Anti-microbial fiber and fibrous products

ABSTRACT

An anti-microbial and/or anti-fungal synthetic fiber and various products made partially or wholly therefrom. The fiber comprises various thermoplastic polymers and additives in a mono-component form or a bi-component form in either a core-sheath or side-by-side configurations. The anti-microbial synthetic fibers comprise inorganic anti-microbial additives, distributed in certain areas to reduce the amount of the anti-microbial agents being used, and therefore the cost of such fibers. The fibers can incorporate anti-microbial additives so that they are not removed by repeated washing in boiling water and in dry clean cycles and become ineffective and conversely enhance access to the additives by washing or the like. The fibers comprise high tenacity polymers (e.g. PET) in one portion and hydrolysis resistance polymers (e.g. PCT) in another portion with the additives. The fibers can further be blended with non-anti-microbial fibers such as cotton, wool, polyester, acrylic, nylon etc. to provide anti-microbial finished fabrics. In one embodiment, binder fibers are used which are mixed with other fibers.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a divisional application of Ser. No.09/565,138 filed May 5, 2000 which claims the priority of the followingprovisional applications: Serial No. 60/136,261, filed May 27, 1999;Serial No. 60/173,207, filed Dec. 27, 1999; Serial No. 60/172,285, filedDec. 17, 1999; Serial No. 60/172,533, filed Dec. 17, 1999; Serial No.60/180,536, filed Feb. 7, 2000; Serial No. 60/181,251, filed Feb. 9,2000; and Serial No. 60/180,240, filed Feb. 4, 2000.

FIELD OF THE INVENTION

[0002] The present invention relates generally to fiber, and, moreparticularly to a fiber having anti-microbial (and/or anti-fungal)properties which remain with the fiber when used in a fabric productafter repeated launderings/uses. More specifically it provides a whollyor partly synthetic fiber and multi- or mono-component anti-microbialand/or anti-fungal synthetic fibers, alone or integrated with othersynthetic or natural fibers, using various thermoplastic polymers andadditives. It may be a bi-component fiber having either a core-sheath orside-by-side configuration or other configurations (e.g. pie-wedge). Onearrangement uses binder fibers, which are staple fiber or filament.

[0003] The present invention further relates to products made wholly orin part of such fiber.

[0004] There is an incontinent garment embodiment which relatesgenerally to garments and other articles, and, more particularly, togarments and other articles which have anti-microbial properties forpeople who are incontinent. Such garments and articles includeunderwear, pajamas, washable and/or disposable diapers, as well aslinens, and bed packs for bed ridden patients, to prevent bed sores.Such garments and articles may be made of woven fabric, knitted fabricor non-woven fabric.

[0005] There is an air filter embodiment which relates to vehicle andaircraft cabin air filters that are made of a wholly or partly syntheticfiber that can be either mono- or multi-component in nature and hasanti-microbial properties and can be used with other synthetic ornatural fibers to form a variety of fabrics and materials. Suchinvention provides for filter materials that are resistant to bacterialand fungal growth as well as to the deterioration of the fiberscontained in these filter materials.

[0006] There is a dressings embodiment which relates to wound carematerials and burn dressings formed of fibers and/or fabrics made of awholly or partly synthetic fiber that can be either mono- ormulti-component in nature and has anti-microbial properties and can beused with other synthetic or natural fibers to form a variety ofdifferent types of fabrics and materials suitable for these uses. Theinvention provides wound care dressings and burn dressings forsuppressing bacterial and fungal growth, and the related risk ofinfection, in materials used for wound care dressings and burndressings.

[0007] There is a fabric embodiment which relates generally to fabricconstruction, and, more particularly, to fabric having qualitiesimparted to it which remain for the life of the fabric, such asexcellent color fastness without the need for a dye bath.

[0008] There is a footwear components embodiment which relates generallyto the footwear art, and, more particularly, to footwear componentshaving anti-microbial properties.

[0009] There is a wide sheet embodiment which relates to wide sheetmaterials that are made of a wholly or partly synthetic material andhaving anti-microbial and anti-fungal properties. Such sheets can beused with other synthetic or natural materials to form a variety ofdifferent end use products. This invention provides for sheet materialsfor end use products that are resistant to bacterial and fungal growthas well as to the deterioration of the agents contained in thesematerials.

[0010] There is also a shoe embodiment which relates to insoles andother shoe products.

[0011] There is a laminate embodiment which relates to generally tolaminate materials, and, more particularly that are made of a whollythermoplastic stiff reinforcing multiple laminate moldable into compoundshapes and bondable via a thermoplastic hot melt adhesive to a carriersurface to be reinforced and suitable for footwear.

[0012] There is an institutional and home furnishings embodiment whichrelates to bed sheets, pillow cases, mattress pads, blankets, towels,drapes, bedspreads, pillow shams, carpets, walk-off mats, napkins,linens, wall coverings, upholstered furniture, liners, mattress ticking,mattress filling, pillow filling, carpet pads, upholstery fabric and thelike. It includes fabrics and materials, and also support substrates andproducts constructed using generally a wholly or partly synthetic fiber(which may be mixed with natural fibers) that can be either mono- ormulti-component in nature and has anti-microbial properties. These arefor use in the home, or in institutional settings such as hotels andmotels, adult communities, offices, hospitals, nursing homes, andprisons.

[0013] There is a medical-healthcare embodiment which relates tomedical/healthcare wipes possessing anti-microbial properties, moreparticularly, to such wipes made of materials and fabrics composed of awholly or partly synthetic fiber that can be either mono- ormulti-component in nature and having anti-microbial properties and canbe used with other synthetic or natural fibers. The invention provideswipes for suppressing bacterial and fungal growth, and the related riskof infection. Such wipes are usually disposable.

BACKGROUND OF THE INVENTION

[0014] There is a growing interest today in products which haveanti-microbial and anti-fungal properties. There are a number ofadditives, fibers and products on the market which claim to have theseproperties. However, many do not have such properties, or the propertiesdo not remain for the life of the product, or they have adverseenvironmental consequences.

[0015] Various materials have been used in the past to provideanti-microbial and anti-fungal properties to fibers and fabrics.

[0016] Examples of some organic types of anti-microbial agents, are U.S.Pat. Nos. 5,408,022 and 5,494,987 (an anti-microbial polymerizablecomposition containing an ethylenically unsaturated monomer, a specificone-, di- or tri-functional anti-microbial monomer and a polymerizationinitiator which can yield an unreleasable anti-microbial polymer fromwhich the anti-microbial component is not released), U.S. Pat. No.5,709,870 (a silver containing anti-microbial agent which comprisescarboxymethylcellulose, a crosslinked compound, containing silver in theamount of 0.01 to 1% by weight and having a degree of substitution ofcarboxymethyl group of not less than 0.4 and the anti-microbial agentbeing a silver salt of carboxymethylcellulose, which is insoluble towater), U.S. Pat. No. 5,783,570 (an organic solvent-solublemucopolysaccharide consisting of an ionic complex of at least onemucopolysaccharide and a quaternary phosphonium, an antibacterialantithrombogenic composition comprising organic solvent-solublemucopolysaccharide and an organic polymer material, an antibacterialantithrombogenic composition comprising organic solvent-solublemucopolysaccharide and an inorganic antibacterial agent, and to amedical material comprising organic solvent-soluble mucopolysaccharide).

[0017] Examples of some inorganic types of anti-microbial agents are:

[0018] Japanese Patent No. 1246204 (1988) which discloses ananti-microbial thermoplastic article with copper a compound added to themelted polymer just before extruding, in which the anti-microbialmaterial is said to be resistant to washing.

[0019] U.S. Pat. No. 5,180,585 which discloses an antimicrobial with afirst coating providing the antimicrobial properties and a secondcoating as a protective layer. A metal having antimicrobial propertiesis used including silver which is coated with a secondary protectivelayer.

[0020] Japanese Patent No. 2099606 (1990) which discloses a fiber withanti-microbial properties made of a liquid polyester and inorganic microparticles of zinc silicate, both being added to the melted polymer afterpolymerization and just before extrusion.

[0021] The use of anti-microbial agents in connection with thermoplasticmaterial is known from U.S. Pat. No. 4,624,679 (1986). This patent isconcerned with the degradation of anti-microbial agents duringprocessing. This patent states that thermoplastic compounds which arecandidates for treatment with anti-microbial agents include materialsuch as polyamides (nylon 6 or 6,6), polyvinyl, polyolefins,polyurethanes, polyethylene terephthalate, styrene-butadiene rubbers.

[0022] Japanese Patent No. 2091009 (1990) and U.S. Pat. No. 5,047,448disclose an anti-microbial thermoplastic polymer with copper or zinccompounds and fine particles of Al, Ag, Fe and Zn compounds and a liquidpolyester, in which the anti-microbial material is said to be resistantto washing.

[0023] Japanese Patent No. 2169740 (1990) discloses a thermoplasticfiber such as PET which uses silver, copper or zinc as an anti-microbialagent. There is a cellulose component which reduces the amount ofthermoplastic with anti-microbial agent and reduces the cost.

[0024] Examples of inorganic types of anti-microbial agent which havezeolite with silver is disclosed in U.S. Pat. Nos. 4,911,898, 5,094,847,4,938,958 (use of zeolite with exchangeable ions such as silver andothers), U.S. Pat. No. 5,244,667 (an anti-microbial composition whichinvolves use of partial or complete substitution of ion-exchangeablemetal ion such a silver, copper, zinc and others), U.S. Pat. No.5,405,644 (an anti-microbial fiber having a silver containing inorganicmicrobiocide and the silver ion is stated to have been supported byzeolite, among other materials, the purpose being to preventdiscoloration).

[0025] Various products have been made using anti-microbial fibers. U.S.Pat. No. 5,071,551 discloses a water purifier having a secondary filterdownstream of its primary filter for removing microorganisms andantimicrobial means disposed between the two filters. use of ananti-microbial agent for a water purifier.

[0026] Japanese Patent No. 6116872 (1994) discloses a suede-likesynthetic leather with an anti-microbial agent. It discloses the use ofanti-microbial zeolite having an anti-microbial metal ion. It uses twofiber types and includes PET.

[0027] U.S. Pat. No. 5,733,949 discloses an anti-microbial adhesivecomposition for dental use. The composition was made by blending of apolymerizable monomer having alcoholic hydroxy group and water to adental composition containing an anti-microbial polymerizable monomerand a polymerizable monomer having acidic group, and with apolymerization catalyst. Such composition has capability to improveadhesive strength between the tooth and the restorative material toprevent microbial invasion at the interface and kill microorganismsremaining in the microstructure.

[0028] U.S. Pat. No. 5,876,489 discloses a germ-removing filter with afilter substrate and an anti-microbial material dispersedly mixed intothe filter substrate. The anti-microbial material is an ion exchangefiber bonded with silver ion. In the ion exchange fiber, silver ionscapable of killing living germs through an ion exchange reaction.

[0029] U.S. Pat. No. 5,900,258 discloses a method for preventing amicroorganism from growing and the breakdown of urea to ammonia on thesurface of skin, wall, floor, countertop or wall covering, or inabsorbent materials by incorporating an effective amount ofnaturally-occurring and/or synthetic zeolites. The absorbent materialsare diapers, clothing, bedsheets, bedpads, surgical apparel, blankets,filters, filtering aids, wall coverings, countertops, and cuttingboards, etc. Use of zeolite preventing bacterial infections and rashesin mammals may compromise cell wall processes including basic transportprocesses. Zeolites may capture or neutralize electrons and inhibitelectron transport through key enzymes of the electron transport chainsuch as cytochrome oxidase.

[0030] U.S. Pat. No. 6,037,057 is for a bi-component fiber in which thecross sectional area of the sheath is less than 28% of the total crosssectional area. It also discloses the use of a slickening agent and useof an anti-microbial agent which is an inert inorganic particle having afirst coating with the anti-microbial properties, and a second coatingwhich has protective properties.

[0031] One of the disadvantages of some of the prior art is that theanti-microbial additives are organic and many organic materials eitheract as antibiotics and the bacteria “learns” to go around the compound,or many of them give off dioxins in use.

[0032] Also, many such additives are applied topically to the fibers orfabrics and tend to wash off or wear off over time and becomeineffective. Also, by washing off the additives are placed into thewaste water stream.

[0033] There are many patents and other published information which areavailable concerning garments and other articles intended for use forincontinent persons. Many of these deal with the problem of moving bodyfluids away from a person's skin to prevent the type of problems createdwhen such fluids remain in contact with the skin for long periods oftime, such as rashes and other skin eruptions. Absorbent layers areprovided behind the layer which touches the skin.

[0034] However, there is the danger of infection due to bacterial andfungal growth in urine-soaked fabrics and the overall discomfort causedby wet clothing.

[0035] There has been little attention to a problem which remains evenwhen the fluids are moved away from the skin. This is the problem causedby microbes which attach to the outer layer which touches the skin evenwhen the fluids move into the absorbent layer. These microbes cause avariety of problems.

[0036] The University of Minnesota Extension Service, Waste EducationSeries published an article in 1998, “Infant Diapers and IncontinenceProducts: Choices for Families and Communities by Gahring et al relatingto this subject (hereafter “UOM Article”). This article indicates thatthe use of disposable diapers and incontinence products have been widelyadopted for babies and for adults with certain problems. There is anestimate that there are at least ten million adult Americans who areincontinent. One of the problems is rashes and skin irritation.

[0037] Moisture absorbing incontinence products are produced in variousmanners including plastic film or coated nylon for a waterproof backing,paper fiber, gelling material, or cotton gauze; flannel for a middleabsorbent layer and nonwoven or woven or knitted fabrics made ofpolyester, olefin, viscose or cotton for the coverstock.

[0038] This article discusses health issues for babies relating to thecondition of the skin and to the transmission of infectious diseases.Prolonged contact with urine and stool is a major cause of diaper rash.

[0039] There are environmental problems associated with the large use ofdisposable products of this type. And this will increase as the numberof elderly people in our society increases. While disposables are placedinto landfills together with other trash, it appears that many people donot empty the contents of disposables into the toilet, and a study hasshown that diaper wastes represent a significant health hazard inlandfills. While many such products claim to be biodegradable, this isnot always correct and there is some difficulty in making the moistureimpervious layers of the plastics used in such products, biodegradable.

[0040] Also it has been found that super-absorbent disposable diapersare more effective than cloth diapers with separate waterproofpants/wraps. The transmission of infectious disease is a major concernfor care, outside of the home. The fecal containment of disposablediapers is found to be significantly better than that of cloth diaperswith plastic pants.

[0041] Vehicle and aircraft cabin air filters are vulnerable to theseeding of bacteria and fungi from outside air sources and airconditioning systems, thus providing hospitable sites for theirinhibited growth. The latter is especially true since these filtersoften recirculate cooled air from air-conditioners. Thus, thesematerials would benefit from having antibacterial and anti-fungal agentsincorporated into them. However, most prior art approaches of coatingfibers or materials with anti-microbial or anti-fungal agents havelimited effect.

[0042] There have been complaints about the “musty air” smell which isnotices when air conditioning equipment is turned on in such cabins.This smell is caused by the growth of mold and bacteria with the airconditioning system.

[0043] There exists a need to develop fabrics and other effectivematerial for use in air filters for vehicle and aircraft cabins that donot cause the development of resistant bacterial strains. There alsostill exists a need for these filters to have substrates-anti-microbialagent systems that are resistant to being washed away, thus maintainingtheir potency as an integral part of the filters into which they areincorporated.

[0044] U.S. Pat. No. 5,876,489, mentioned above, describes use of acation exchange to provide a fiber bonded with silver ions, usable in agerm removing filter for sterilizing air for a sterile room such as isused in the manufacture of food products. A problem with using silverzeolite fine particles for such a filter is that the particles fall outand generate dust, thereby deteriorating the function of a HEPA filterwith which it is used. When other methods are used in which the zeoliteparticles are two microns, with fiber filament having a diameter of 8-15microns, insufficient zeolite particles are available on the surface ofthe synthetic fiber filament.

[0045] Wound care dressings can introduce pathogens that increase thedanger of infection due to bacterial and fungal growth into the woundtissue because it is necessary to changing these dressings frequently.As a result of the constant re-exposure of the healing wound to the air,the dressings used to cover these wounds are suitable for the use ofanti-microbial and anti-fungal fibers during their manufacture. Inaddition, the use of these anti-microbial materials could allow thesedressings to be used for longer periods of time before they need to bechanged or even to possibly be reusable, although they are usuallyconsidered disposable after one use. However, most prior art approachesof coating such fibers or fabrics with anti-microbial or anti-fungalagents have had limited success.

[0046] Burn dressings are used to prevent infection due to highpotential for introducing bacteria and other pathogens into the burntissue due to the fact that the normal protective barrier of the skinhas been grossly disrupted. The possibility of bacterial and fungalgrowth in the burn tissue during healing is one of the major dangers torecovery. Also, as a result of the constant re-exposure of the healingburn tissue to the air during the changing of dressings, the materialsused to protect these burns are suitable for the use of anti-microbialand anti-fungal fibers during their manufacture. In addition, the use ofthese anti-microbial materials could allow these burn dressings to beused for longer periods of time before they need to be changed.

[0047] Several patents describe anti-microbial materials in which theanti-microbial agent is resistant to being washed away. Similarly, U.S.Pat. No. 4,919,998 (1990) discloses an anti-microbial medical fabricmaterial for use in surgical gown and scrub suits, sterilizationwrappers and similar material that retains its desirable propertiesafter repeated institutional launderings.

[0048] U.S. Pat. No. 4,226,232 discloses a wound dressing which providesmany desirable properties. However, there is only brief mention of theuse of anti-microbial agents, and there is no discussion of providingsuch agents onto the surface of the fibers contacting the wound toprovide the best efficacy of anti-microbial agents.

[0049] U.S. Pat. No. 5,098,417 for a cellulosic wound dressing with anactive agent ionically absorbed thereon has the anti-microbial oranti-fungal agent applied to an already prepared fabric.

[0050] U.S. Pat. No. 5,147,339 for a dressing material for the treatmentof wounds has an anti-microbial applied to the already formed fabric asa coating.

[0051] U.S. Pat. No. 5,219,325 for a wound dressing has a top layer anda lower layer (which contacts the wound) connected together by a fibrouslayer. The lower layer has an anti-microbial applied after the layer isformed.

[0052] Thus, there still exists a need to develop metal-containinganti-microbial agents that do not cause the development of resistantbacterial strains for incorporation into fibers that are used to make avariety of materials. There also still exists a need for theseanti-microbial agents to be resistant to being abraded or washed away,thus maintaining their potency as an integral part of the fibers intowhich they are incorporated.

[0053] PETG as used herein means an amorphous polyester of terephthalicacid and a mixture of predominately ethylene glycol and a lesser amountof 1,4-cyclohexanedimethanol. It is known that PETG can be used inpolycarbonate blends to improve impact strength, transparency,processability, solvent resistance and environmental stress crackingresistance.

[0054] Udipi discloses in U.S. Pat. Nos. 5,104,934 and 5,187,228 thatpolymer blends consisting essentially of PC, PETG and a graft rubbercomposition, can be useful as thermoplastic injection molding resins.

[0055] Chen et al. in U.S. Pat. No. 5,106,897 discloses a method forimproving the low temperature impact strength of a thermoplasticpolyblend of PETG and SAN with no adverse effect on the polyblendsclarity. The polyblends are useful in a wide variety of applicationsincluding low temperature applications.

[0056] Billovits et al. in U.S. Pat. No. 5,134,201 discloses thatmiscible blends of a thermoplastic methylol polyester and a linear,saturated polyester or co-polyester of aromatic dicarboxylic acid, suchas PETG and PET, have improved clarity and exhibit an enhanced barrierto oxygen relative to PET and PETG.

[0057] Batdorf in U.S. Pat. No. 5,268,203 discloses a method ofthermoforming thermoplastic substrates wherein an integral coating isformed on the thermoplastic substrate that is resistant to removal ofthe coating. The coating composition employs, in a solvent base, apigment and a thermoplastic material compatible with the to-be-coatedthermoplastic substrate. The thermoplastic material, in cooperation withthe pigment, solvent and other components of the coating composition,are, after coating on the thermoplastic substrate, heated to athermoforming temperature and the thermoplastic material is intimatelyfused to the thermoplastic substrate surface.

[0058] Ogoe et al. in U.S. Pat. No. 5,525,651 disclose that a blend ofpolycarbonate and chlorinated polyethylene has a desirable balance ofimpact and ignition resistance properties, and useful in the productionof films, fibers, extruded sheets, multi-layer laminates, and the like.

[0059] Hanes in U.S. Pat. No. 5,756,578 discloses that a polymer blendcomprising a monovinylarene/conjugated diene black copolymer, anamorphous poly(ethylene terephthalate), e.g. PETG, and a crystallinepoly(ethylene terephthalate), e.g. PET, has a combination of goodclarity, stiffness and toughness.

[0060] Eckart et al. in U.S. Pat. No. 5,958,539 disclose a novelthermoplastic article, typically in the form of sheet material, having afabric comprising textile fibers embedded therein. The thermoplasticarticle is obtained by applying heat and pressure to a laminatecomprising an upper sheet material, a fabric comprised of textile fibersand a lower sheet material. The upper and lower sheet materials areformed from a co-polyester, e.g. PETG. This thermoplastic article may beused in the construction industry as glazing for windows. One or bothsurface of the article may be textured during the formation of thearticles.

[0061] Ellison in U.S. Pat. No. 5,985,079 discloses a flexible compositesurfacing film for providing a substrate with desired surfacecharacteristics and a method for producing this film. The film comprisesa flexible temporary carrier film and a flexible transparent outerpolymer clear coat layer releasably bonded to the temporary carrierfilm. A pigment base coat layer is adhered to the outer clear coat layerand is visible there through, and a thermo-formable backing layer isadhered to the pigmented base coat layer. The film is produced byextruding a molten transparent thermoplastic polymer and applying thepolymer to a flexible temporary carrier thereby forming a continuousthin transparent film. The formed composite may be heated while thetransparent thermoplastic polymer film is bonded to the flexibletemporary carrier to evaporate the volatile liquid vehicle and form apigment polymer layer. The heating step also molecularly relaxes theunderlying film of transparent thermoplastic polymer to relieve anymolecular orientation caused by the extrusion. Ellison also mentionsthat it is desirable to form the flexible temporary carrier from amaterial that can withstand the molten temperature of the transparentthermoplastic polymer. The preferred flexible temporary carriers used inhis invention are PET and PETG.

[0062] Currently, many tee shirts, such as the grey athletic shirts, aremade by blending in up to 10% of either solution dyed black polyester orstock dyed cotton. The solution dyed polyester has a disadvantage inthat the product can no longer be labeled 100% cotton. The stock dyedcotton has the disadvantage in that it is not color fast, especially tobleach, and that it needs to be passed through a dye bath.

[0063] While anti-microbial agents are known in the footwear art, theagents used in these applications are generally organic substances. Thedisadvantage of these organic agents when used as anti-microbial agentsis that bacteria can develop a resistance to their action. Thus, one isfaced with the emergence of bacterial strains that are no longeraffected by these anti-microbial agents which negates the function ofthese materials, and is harmful to humans since they are resistant toantibiotics.

[0064] One type of known shoe component is an insole disclosed in U.S.Pat. No. 4,864,740 for Disposable Insoles, which includes three layersin which the anti-microbial agent is placed into the middle layer. As analternative, the anti-microbial can be placed into the other layers,disclosing that the particular layer into which the anti-microbial agentis used is not important.

[0065] U.S. Pat. No. 4,401,770 for Shoe Insole Having Anti-bacterial andAnti-fungal Properties is a flexible polyurethane foam prepared from areaction mixture incorporating an anti-bacterial and anti-fungal agentwhich is a pyridinethione compound. The agent is introduced into theproduct and is the same concentration throughout the product.

[0066] Thus, there still exists a need to develop anti-microbialfootwear components that do not cause the development of resistantbacterial strains. There also still exists a need for these componentsto have anti-microbial agent systems that are resistant to being wornaway by abrasion, thus maintaining their potency as an integral part ofthe footwear components into which they are incorporated.

[0067] Sheet materials for various uses are vulnerable to the seeding ofbacteria and fungi from various sources, thus providing hospitable sitesfor their uninhibited growth. The latter is especially true since,depending upon the end use, they often are used in environments wherethere is great exposure to microbes and fungi. One example is cafeteriatrays. Thus, these materials would benefit from having antibacterial andanti-fungal agents incorporated onto them and/or into them. However,most prior art approaches of providing sheet materials withanti-microbial or anti-fungal agents have limited effect.

[0068] A variety of patents relate to anti-microbial materials beingadded to materials. For example, U.S. Pat. No. 3,959,556 (1976) relatesto synthetic fibers that incorporate an anti-microbial agent. U.S. Pat.No. 4,624,679 (1986), mentioned above, uses anti-microbial agents inconnection with thermoplastic materials. These materials are formed bymixing polyamide resins, anti-microbial agents, and an antioxidant forreducing the degradation of the anti-microbial agent at the hightemperatures necessary for processing.

[0069] Several other patents describe anti-microbial materials in whichthe anti-microbial agent is resistant to being washed away. U.S. Pat.No. 4,919,998 (1990) discloses an anti-microbial material that retainsits desirable properties after repeated washings.

[0070] However, these materials have two inherent commercialdisadvantages. First, while the anti-microbial agents incorporated intothem do show some resistance to repeated washings, these agents do leachout of the materials, primarily because they are not physicallyincorporated into them. In fact, in many cases, the anti-microbialagents are only loosely bound into the material and are relativelyeasily washed away or naturally abraded away over time.

[0071] On the other hand if the agents are buried too deeply in thematerial or homogeneously distributed they will not contact microbes atall and the economics of usage will be adversely affected.

[0072] Second, the anti-microbial agents used in these applications aregenerally organic substances. The disadvantage of these agents when usedas anti-microbial agents is that bacteria can develop a resistance totheir action. Thus, one is faced with the emergence of bacterial strainsthat are no longer affected by these anti-microbial agents which negatesthe function of these materials.

[0073] U.S. Pat. No. 4,923,914 for a Surface-Segregatable,Melt-Extrudable Thermoplastic Composition discloses forming a fiber orfilm of polymer and an additive in which the additive concentration isgreater at the surface. for example when surfactants are added topolymers to impart a special property thereto such as a hydrophiliccharacter to the surface, if the additive is compatible with the polymerthere is a uniform concentration of the additive throughout the polymer.In the past such webs have been bloomed to bring the surfactant to thesurface. But the surfactant is incompatible at melt-extrusiontemperatures. The patentee describes a process for overcoming thisproblem.

[0074] However, the process described has not been very usable withanti-microbial agents. For example, see U.S. Pat. No. 5,280,167 whichdescribes the '914 patent discussed above and states that previousattempts to apply the teachings thereof to the preparation of non-wovenwebs having anti-microbial activity were not successful. This '167patent provides for delayed anti-microbial activity in order to delaythe segregation characteristic of the '914 patent from occurring. Theadditive which is used is a siloxane quaternary ammonium salt, anorganic material.

[0075] While these anti-microbial agents are designed to prevent thedevelopment of resistant bacterial strains, the use of metal-containingmaterials presents the added difficulty of being able to successfullydisperse the anti-microbial agents throughout the material. Since thesemetal-containing compounds exists as fairly large size particles (10microns and greater), the ability to evenly mix or distribute them islimited. In addition, because of this size problem, these substancesmust necessarily be applied to the surfaces of materials instead ofbeing incorporated into them. The latter causes the additionaldisadvantage of making the applied anti-microbial agents relativelylabile to washings or abrasion.

[0076] Thus, there still exists a need to develop anti-microbialnon-woven sheet material and fabrics for various uses that do not causethe development of resistant bacterial strains. There also still existsa need for these filters to have substrates-anti-microbial agent systemsthat are resistant to being washed away, thus maintaining their potencyas an integral part of the filters into which they are incorporated.

[0077] U.S. Pat. No. 4,350,732 for reinforcing laminate which issuedSep. 21, 1982 discusses a moldable laminate which could be molded intocurved shapes and which is bondable to a carrier surface and which isuseful in the making of military boots and the like. The presentinvention is an improvement.

[0078] Institutional furnishings are subject to excessive wear and tear.These furnishings must withstand the constant onslaught of dirt andspills of a variety of substances. They must also stand up to frequentcleanings with industrial strength cleansers. As a result, thesefurnishings could be made stronger and more resistant by usinganti-microbial and anti-fungal agents in their manufacture. The limitedprior art approaches of coating fibers and/or fabrics withanti-microbial or anti-fungal materials have had only limited success.

[0079] Home furnishings are not subjected to as much wear and tear asinstitutional furnishings and are usually made of a material which has asofter “feel” and is usually more delicate than those made forinstitutional use. Therefore, it is difficult to make such materialswhich will stand up to repeated washings and to wear, particularly whenthey have been prepared with additives for special properties such asanti-microbial agents.

[0080] U.S. Pat. No. 3,983,061 for a process for the permanent finishingof fiber materials, including carpets, discloses an aqueous acid liquidfor finishing fiber materials especially dyed carpets to make themanti-static, dirt-repellent, and optionally anti-microbial using asingle bath process for finishing dyed textile floor coverings to makeprovide these characteristics to them. It states that the properties are“permanent” and defines this to mean retaining the properties after a“prolonged” period of wear and tear. However, the anti-microbialproperties are not believed to last sufficiently long to be ofcommercially useful application, and the anti-microbial agent disclosedis organic in nature.

[0081] U.S. Pat. No. 4,371,577 for an anti-microbial carpet containingamino acid type surfactant is incorporated into fibrous materials priorto or after fabrication into a carpet using an organic material. Thefibrous materials can be polyamide acrylic, polyester or polypropylenefibers. The preparation is accomplished in two manners. The first isthat the pile yarns, the carpet foundations or the yarns for carpetfoundation are subjected to the impregnation treatment with asurfactant, and the other is that a carpet fabricated from fibrousmaterials is impregnated with an organic material.

[0082] U.S. Pat. No. 5,762,650 for a biocide plus surfactant forprotecting carpets where the dyeing and anti-microbial finishing isperformed simultaneously. The anti-microbial agent is an organicmaterial.

[0083] While there are known anti-microbial agents which are said to bedesigned to prevent the development of resistant bacterial strains, theuse of metal-containing materials presents the added difficulty of beingable to successfully disperse the anti-microbial agents throughout thefibers. Since these metal-containing compounds exist as fairly largesize particles (10 microns and greater), the ability to evenly mix ordistribute them is limited. In addition, because of this size problem,these substances must necessarily be applied to the fibers instead ofbeing incorporated into them. The latter causes the additionaldisadvantage of making the applied anti-microbial agents relativelylabile to washings.

[0084] Thus, there still exists a need to develop fabrics, materials andsurfaces substrates for use in home and institutional furnishings whichcontain metal-containing anti-microbial agents that do not cause thedevelopment of resistant bacterial strains for incorporation into fibersthat are used to make a variety of fabrics. There also still exists aneed for these anti-microbial agents to be resistant to being washedaway, thus maintaining their potency as an integral part of the fibers,fabrics, materials, and furnishings into which they are incorporated.

[0085] Medical wipes are used for a variety of cleaning and disinfectantpurposes in hospital and other institutional settings. Even though mostcurrent materials of this kind are disposable, their use increases thepotential of moving pathogens from surface to surface. Any spreading ofthese pathogens increases the possibility of bacterial and fungal growthon a variety of surfaces, which can lead to the transmission ofinfectious materials, particularly in institutional settings. Thus, thematerials used in medical wipes are amenable to the incorporation ofanti-microbial and anti-fungal fibers during their manufacture. By usingthese anti-microbial materials, medical wipes could be used for longerperiods of time before they need to be changed. However, most prior artapproaches of coating fibers or fabrics with anti-microbial oranti-fungal agents have had limited success.

[0086] U.S. Pat. No. 5,709,870 (1998), mentioned above, discloses asilver-containing anti-microbial agent that has good affinity to thefiber and is stable to heat and light. The anti-microbial consists ofsilver bound to carboxymethylcellulose in the amount of 0.01 to 1.0percent silver by weight that is applied to the fibers.

[0087] While these anti-microbial agents are designed to prevent thedevelopment of resistant bacterial strains, the use of metal-containingmaterials presents the added difficulty of being able to successfullydisperse the anti-microbial agents throughout the fibers. Since thesemetal-containing compounds exists as fairly large size particles (10microns and greater), the ability to evenly mix or distribute them islimited. In addition, because of this size problem, these substancesmust necessarily be applied to the fibers instead of being incorporatedinto them. The latter causes the additional disadvantage of making theapplied anti-microbial agents relatively labile to washings.

[0088] Thus, there still exists a need to develop metal-containinganti-microbial agents that do not cause the development of resistantbacterial strains for incorporation into fibers that are used to make avariety of materials. There also still exists a need for theseanti-microbial agents to be resistant to being abraded away, thusmaintaining their potency as an integral part of the fibers into whichthey are incorporated. In the event they are not disposable, they needto be resistant to washings.

SUMMARY OF THE INVENTION

[0089] It is an object of the present invention to provide ananti-microbial fiber in which the anti-microbial agents are efficaciousand adhere to the fiber and are greatly resistant to washing off orwearing off of the fiber or fabric to which they are applied.

[0090] It is also an object of the present invention to provide ananti-microbial fiber in which the anti-microbial additives areinorganic.

[0091] It is another object of the present invention to provide a fiberwith anti-microbial properties in which the anti-microbial agent isapplied to certain areas, or has higher concentrations in certain areas,to reduce the amount of the anti-microbial agent which needs to be usedand thus lower the cost of such fiber and/or a fabric including suchfiber.

[0092] It is another object of the present invention to provide ananti-microbial fiber combined with non-anti-microbial fibers for use inanti-microbial finished fabrics that are able to withstand significantwear and washings and still maintain their effectiveness.

[0093] It is a further object of the present invention to provide ananti-microbial fiber:

[0094] combined with color pigments for coloration for the use inanti-microbial finished fabrics to withstand fading;

[0095] combined with UV additives to withstand fading and degradation infabrics exposed to significant UV light;

[0096] combined with additives to make the surface of the fiberhydrophilic or hydrophobic;

[0097] combined with additives to make the fabric flame retardant orflame resistant;

[0098] combined with additives to make the fabric anti-stain; and/or

[0099] using pigments with the anti-microbial so that the need forconventional dyeing and disposal of dye materials is avoided.

[0100] These and other objects of the present invention are accomplishedby synthetic fibers having anti-microbial and/or anti-fungal propertiesusing various thermoplastic polymers blended with other types of fibers,and additives, some incorporating natural fibers.

[0101] Thus, the present invention provides a synthetic anti-microbialfiber comprising high and low levels of various thermoplastic polymersand controlled concentrations of inorganic anti-microbial additivesmixed with polymers and selectively placed in the end product forgreatest technical effectiveness and cost effectiveness.

[0102] The anti-microbial and/or other agent(s) are held in the sheathand are exposed externally by suitable sizing of particle cubes andsheath thickness, e.g., using one micron cubes and 2 micron thicksheaths, and similar ratios of sheath to core in other sizes.

[0103] The present invention also provides a synthetic anti-microbialfiber comprising high tenacity polymers e.g. polyesters, polyethyleneterephalate (PET) in one portion and hydrolysis resistance polymers inanother portion with hydrophilic and anti-microbial additives. In someapplications the latter portion can be deliberately madehydrolysis-vulnerable to allow “blooming” and enhanced access toanti-microbial additives in the course of several washings or extendeduses.

[0104] Also, the present invention provides an anti-microbial finishedfabric by blending the synthetic anti-microbial fibers withnon-anti-microbial fibers such as cotton, wool, polyester, acrylic,nylon, and the like.

[0105] The various polymers, include but are not limited to,polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET),PCT, PETG [PET, type G], Co-PET and copolyesters generally, Styrene,polytrimethylene terephalate (PTT)m 3GT, Halar®, polyamide 6 or 6,6,etc. The additives include pigments, hydrophilic or hydrophobicadditives, anti-odor additives and anti-microbial/anti-fungal inorganiccompounds, such as copper, zinc, tin and silver.

[0106] PETG is an amorphous binder fiber which can be blended into yarnswith other fibers to form fabrics, as well as non-woven fabrics. Afterheat activation, the PETG fiber melts, wets the surface of thesurrounding fibers, and settles at the crossing points of the fibers,thus forming “a drop of glue” which bonds the fibers together anddistributes the anti-microbial additives.

[0107] The excellent wetting characteristics of PETG can be used todistribute the anti-microbial additive uniformly within a yarn orfabric. In addition to the zeolite of silver, the PETG could carry otherinorganic anti-microbial additives such as copper, zinc, or tin.

[0108] In addition to the anti-microbial component, the invention may beused to carry pigments with the PETG to achieve certain colors withoutthe need to dye the other fibers.

[0109] The created synthetic fibers of polymers and additives canfurther be blended with non anti-microbial fibers to provideanti-microbial finished fabrics that are able to withstand significantwear and washings and maintain their effectiveness.

[0110] The use of hot water improves the products in that washing thefibers/products in hot water opens the pores of the PET and such washedproducts perform better than unwashed products (this is thought to bedue to the removal of spinning/weaving lubricants).

[0111] Material can be made in biodegradable form, such as by addingcorn starch to the core or sheath polymers. This enables whole familiesof disposable fibers and fabrics.

[0112] Use of a cloth diaper and a garment over it is effective,especially when anti-microbial/anti-fungal fibers are used for thefibers which have contact with the waste matter, although beneficialeffects are available even when the anti-microbial/anti-fungal agentsare used only in the fibers which touch the body.

[0113] Due to the urine soaking which occurs with incontinent persons,these garments are suitable for the use of anti-microbial andanti-fungal fibers during their manufacture. The use of suchanti-microbial material allows these garments to be reusable without thenegative effects of present reusable garments of this type. Theanti-microbial may be fabric (knitted or woven) plus absorbent pads.This also applies to bed packs for bed ridden patents to prevent bedsores.

[0114] It is an object of the incontinent garment embodiment to providegarments and articles intended for use for incontinent persons whicharticles have anti-microbial and/or anti-fungal fibers in a woven ornon-woven fabric of the garment or article which is in contact with suchperson's skin to eliminate or substantially reduce the problems causedby such microbes.

[0115] It is another object of the incontinent garment embodiment toprovide such garments and articles which may be cleaned and reused manytimes while maintaining the beneficial anti-microbial qualities thereof.

[0116] It is a further object of the incontinent garment embodiment toprovide anti-microbial fibers in the absorbent material usually used insuch articles.

[0117] Thus, there still exists a need to develop garments and articlesof the type described which are made of fibers having metal-containinganti-microbials that do not cause the development of resistant bacterialstrains for incorporation into fibers that are used to make a variety offabrics. There also still exists a need for these anti-microbial agentsto be resistant to being washed away, thus maintaining their potency asan integral part of the garments and articles into which they areincorporated.

[0118] It is a principal object of the air filter embodiment to providevehicle and aircraft cabin air filter materials that meet these needs ina manner consistent with industry specifications, overall durability,and cost-effectiveness.

[0119] It is another object of the air filter embodiment to provide suchfilters which are effective to eliminate or at least substantiallyreduce the “musty air” smell noticed in such cabins.

[0120] The foregoing objects are met by filters based on anti-microbialfibers that have been designed using inorganic silver-containingcompounds that allow the formation of both mono- and multi-componentpolymeric fibers having these anti-microbial agents intermixed withinthe polymer during fiber formation. The concentration of theanti-microbial agent can be varied within each individual fiber as agradient using mixing strategies and also from fiber to fiber. Theconcentration of anti-microbial agent within a fabric or material madefrom these anti-microbial fibers can also be varied regionally usingfibers containing varying amounts of anti-microbial agents inconjunction with both natural and synthetic fibers having differentamounts of anti-microbial agents or even no added anti-microbial agents.A variety of other agents can be added, either by mixing or topically,to color the fibers and/or to make it resistant to staining, fire, andultraviolet (UV) light as well as altering its water absorbingqualities. Various polymers, without limitation, can be used to formthese fibers. In the context of this invention, anti-microbial refers,but is not limited, to antibacterial and anti-fungal.

[0121] It is an object of the wound and burn dressings embodiment toprovide wound care dressings that meet these needs with attendantdurability and comfort in a cost-effective manner.

[0122] It is another object of the wound and burn dressings embodimentto provide wound care dressings that are one time use products havingdurability and workability.

[0123] A further object of the wound and burn dressings embodiment is toprovide such dressings in which the anti-microbial agent is available atthe surface of the fibers.

[0124] It is the object of the wound and burn dressings embodiment toprovide burn dressings that meet these needs with substantial durabilityand comfort in a cost-effective manner.

[0125] Still a further object is to provide a dressing which is usefulby itself, or in combination with other wound dressing systems to addfibers to such a system which are in direct or near contact with thewound to provide anti-microbial agents on the surface of the fibersclosest to the wound.

[0126] Yet a further object of the wound and burn dressings [invention]embodiment is to provide such a dressing which maintains its vigor evenafter any liquid or cream anti-microbial agents that may be usedtherewith have lost their efficacy or have left the dressing and wounddue to movement of the patent and the dressing itself.

[0127] The foregoing objects are met by wound care and burn dressingsbased on anti-microbial fibers that have been designed using inorganicsilver-containing compounds that allow the formation of both mono- andmulti-component polymeric fibers having these anti-microbial agentsintermixed within the polymer during fiber formation. The concentrationof the anti-microbial agent can be varied within each individual fiberas a gradient using mixing strategies and also from fiber to fiber. Theconcentration of anti-microbial agent within a fabric or material madefrom these anti-microbial fibers can also be varied regionally usingfibers containing varying amounts of anti-microbial agents inconjunction with both natural and synthetic fibers having differentamounts of anti-microbial agents or even no added anti-microbial agents.A variety of other agents can be added, either by mixing or topically,to color the fibers and/or to make it resistant to staining, fire, andultraviolet (UV) light as well as altering its water absorbingqualities. Various polymers, without limitation, can be used to formthese fibers. In the context of this invention, anti-microbial refers,but is not limited, to antibacterial and anti-fungal.

[0128]FIG. 10 shows a wound care dressing 52 which includes a bottomlayer 46, a top layer 48 and an intermediate absorbent fibrous layer 50which joins the other two layers. The bottom layer 46 is used directlyagainst the wound and therefore the fibers of this layer have theanti-microbial agent applied thereto as described below.

[0129] The invention uses fibers with silver zeolite as a component in awound dressing pad. The finished product may be either the pad itselfor, the pad combined to PVC, adhesive or other materials. The wounddressing pad may be woven, knit, non-woven or other fabric type and maycontain any variety of natural or synthetic fibers in addition to theanti-microbial fibers. The pad may or may not have a cover stock overit, as well as other medicated treatments.

[0130] The purpose is to help prevent the growth of microbes in/on awound care dressing, as well as the wound area, as it heals. The theoryhere is that a reduction in microbes/bacteria will facilitate healingand minimize the potential for infections.

[0131] Infections are a significant concern with wound care and burncare. body fluids at the wound on burn site provide both the “food” andmoisture for GHC microbial growth.

[0132] A dressing media containing an anti-microbial additive wouldprevent the growth of microbes in the media in contact with the wound orburn. This may allow the dressing to remain in place longer and reducethe trauma when a “dressing is changed.”

[0133] It is one object of the fabric embodiment to provide a fiberwhich is used to form a fabric to which qualities may be imparted whichlast for the life of the fabric.

[0134] It is another object of the fabric embodiment to provide such afabric which is provided with coloring which remains fast even tosunlight and many launderings.

[0135] It is a further object of the fabric embodiment to provide such afabric which is provided with a colorant without the use of a dye bath.

[0136] It is still another object of the fabric embodiment to provide afiber and fabric of the type described which possesses anti-microbialproperties.

[0137] It is yet another object of the fabric embodiment to provide afiber and fabric of the type described in which characteristics may beimparted using agents which become permanently fixed and are maintainedfor the life of the fabric.

[0138] These objects and others are accomplished in accordance with thepresent invention which uses PETG:

[0139] As a carrier for pigments for coloration for use in finishedfabrics to withstand fading;

[0140] With pigments together with other fibers, so that the need forconventional dyeing and disposal of dye materials is avoided;

[0141] With pigments and other fibers, and the resulting fabricpossesses excellent fastness for both sunlight resistance and washing;

[0142] With pigments for coloration, the color of the fabric remainsfast for in excess of 50 commercial launderings;

[0143] With pigments blended with cotton, which leaves the encapsulatedpigment attached to the outside of the cotton fiber and ceases to be afiber after activation, so that the resulting fabric can still belabeled 100% cotton fiber; and

[0144] With anti-microbial and/or other additives with any naturalfibers, so that the resulting fabrics have anti-microbial and/or otherproperties with the same characteristics of natural fabrics.

[0145] PETG may be used as one of the polymer blends and/or carriers fora wide variety of applications. PETG is an amorphous binder fiber thatcan be blended into yarns with other fibers to form woven fabrics, aswell as knits and non-woven fabrics. It has two characteristics ofparticular interest: (1) excellent wetting and (2) low meltingtemperature (which can be controlled between 90° C. and 160° C.). It isused in the present invention as a carrier to carry pigments and/oranti-microbial additives and/or other additives and is blended withother fibers which may be natural fibers such as cotton, silk, flax,wool, etc. or other synthetic fibers such as: PET, PP, PE, Nylon,Acrylic, etc. After heat activation, the PETG melts, continuouslyreleases the color pigments and/or anti-microbial or other additives andwets the surface of the surrounding fibers with the pigment and/oranti-microbial or other additives it carries. It settles at the crossingpoints of the fibers, thus forming “a drop of glue” which bonds thefibers together. Therefore, PETG delivers and distributes the pigmentsand/or anti-microbial or other additives uniformly within a fabric,generating the finished fabrics and/or fabrics having anti-microbialproperties.

[0146] Since the natural fibers used to blend with PETG are not changedphysically after heat activation of PETG, they contain the samecharacteristics as natural fibers. The PETG may be used together with orwithout anti-microbial agents to form a fabric having excellent colorfastness even in the presence of sunlight, and will withstand manywashings without deterioration. The fabric is made by blending PETG usedas a carrier for pigments and/or anti-microbial additives, with cottonor any other fibers of synthetic material such as from polyester andrayon, and activating PETG from 110° to 140° C. The color is thusprovided to the yarn and fabric without the need of going through a dyebath. This fabric remains color-fast for in excess of 50 commerciallaunderings.

[0147] The excellent wetting characteristics of PETG can be used todistribute the pigments and/or anti-microbial additive uniformly withina yarn or fabric. While many anti-microbial agents may be used, such asthose, which use copper, zinc, or tin, the preferred agent is zeolite ofsilver. In addition to the anti-microbial component and the pigmentadded to the PETG, the PETG may be used as a carrier to add otherproperties to yarn and fabric, such as fire retardants.

[0148] It is a principal object of the footwear components embodiment toprovide such footwear components that meet these needs in a mannerconsistent with industry specifications, overall durability, andcost-effectiveness.

[0149] It is another object of the footwear components embodiment toprovide such footwear components in various forms such as rigid,semi-rigid or flexible and which may be constructed using fibers or notas desired.

[0150] A further object of the footwear components embodiment is to havethe anti-microbial agent as close as possible to a person's foot.

[0151] An additional object of the footwear components embodiment is tohave a higher concentration of the anti-microbial and/or anti-fungalagent close to the surface and not wasted by being placed into otherparts of the where the anti-microbial property is not needed.

[0152] The foregoing objects are met by footwear components such asinsoles, midsoles, box toes, counter and linings of footwear products,e.g., shoes, slippers, sneakers and the like in which the anti-microbialagent is available for the life of the product and not washed away orworn away by sweat or abrasion. Also, the anti-microbial agent is placedinto the component close to or on the surface which is most needy of theprotection, such as the part of an insole closest to the foot of a userwhen the insole, or other component is assembled into a footwearproduct. Thus, the fungi or microbes which may form and create odors orother problems are killed on contact with the surface of the shoecomponent anti-microbial surface area.

[0153] The footwear component of the disclosed products can be anonwoven fabric of synthetic fibers, primarily polyester, but whichcould be acrylic, nylon, rayon, acetate, PP, and the like. The fabriccan have a weight from 65-400 grams per square meter and typical fibersrange from 1.2 dTex to 17 dTex with a cut length of 15-180 mm. They arecarded, cross-lapped and needle punched, but could be produced on othertypes of nonwoven equipment, such as spun laced or spun bondedequipment.

[0154] The impregnation is a latex of SBR, vinyl acetate, PVC,acrylonitrile, and the like. Impregnation is from 1-4 times the weightof the nonwoven fabric on a dry basis. A range of fillers such as clay,calcium carbonate, and the like are used to reduce the cost. There aretwo basic methods. One is to mix the anti-microbial with latex compoundand impregnate it into the insole. The other is to use anti-microbialfibers on the insole in various manners.

[0155] It is a principal object of the present film embodiment toprovide such sheet and film materials that meet these needs in a mannerconsistent with industry specifications, overall durability, andcost-effectiveness.

[0156] It is another object of the film and sheet embodiment [presentinvention] to provide such sheet materials in various forms such asrigid, semi-rigid or flexible and which may be constructed covered withthin films, or not, as desired.

[0157] The foregoing objects are met by sheet and film materials of ananti-microbial non-fibrous material such as melted thermoplasticmaterial that has been designed using inorganic silver-containingcompounds that allow the formation of both mono- and multi-layerpolymeric materials having these anti-microbial agents intermixed withinthe polymer during material formation.

[0158] The anti-microbial will usually be included at and near thesurface of a thin layer such as a film. The concentration of theanti-microbial agent can be varied as a gradient using mixingstrategies. The concentration of anti-microbial agent within or on thesurface of sheet material can also be varied regionally using materialscontaining varying amounts of anti-microbial agents in conjunction withboth natural and synthetic materials having different amounts ofanti-microbial agents or even no added anti-microbial agents. A varietyof other agents can be added, either by mixing or topically, to colorthe material and/or to make it resistant to staining, fire, andultraviolet (UV) light as well as altering its water absorbingqualities. Various polymers, without limitation, can be used to formthese fibers. In the context of this invention, anti-microbial refers,but is not limited, to antibacterial and anti-fungal.

[0159] The present invention provides several embodiments, one of whichrelates to the co-extrusion of flat or shaped films or profiles. Theproduct may be a multi-layer construction with the surface layer, on oneor both sides, containing zeolite of silver (or other metal such as tin,copper, zinc, etc.).

[0160] The product may be a flat film for use in a flat form for countertops, floors, walls, or molded into shapes such as cafeteria trays,serving dishes, high chair table, refrigerator trays, microwave liners,and luggage.

[0161] As a profile the extrusion may be a rain gutter, a screenenclosure, a counter top, hand railing, duct work, sanitary piping,water pipe, gasket materials, around dishwasher, garage door), etc.

[0162] The same concept applies to multi-layer injection molded parts.In this case the surface layer may have anti-microbial properties inapplications such as telephone handsets, baby bottles, computerkeyboards, plastic utensils, and milk bottles.

[0163] The choice of particle size of the zeolite is based on thethickness of the film to obtain the best combination of surface areawith anchoring in the film. For example, a very thin film of 3 m wouldbe best served with a 1-2 m zeolite, which would have a maximumdimension of 2×1.73 or about 3.5 m.

[0164] The inner films could be made of basically any thermoplasticresin, such as; PE, PP, PET, PS, PCT, Polyamide (nylon), Acrylic, PVC,etc. The surface layer(s) could be made of the same polymers plus somelow temperature ones such as PETG, Polycaprolactone, EVA, etc.

[0165] It is a principal object of the present embodiment to providesuch sheet and film materials that meet these needs in a mannerconsistent with industry specifications, overall durability, andcost-effectiveness.

[0166] The foregoing objects are met by sheet and film materials of ananti-microbial non-fibrous material such as melted thermoplasticmaterial that has been designed

[0167] Home and institutional furnishings are provided which are madefrom fibers, yarns, fabrics, materials, and substrates havinganti-microbial properties using inorganic silver-containing compounds.This allows, for example, the formation of both mono- andmulti-component polymeric fibers having these anti-microbial agentsintermixed within the polymer during fiber formation. The concentrationof the anti-microbial agent can be varied within each individual fiberas a gradient using mixing strategies and also from fiber to fiber. Theconcentration of anti-microbial agent within a fabric or material madefrom these anti-microbial fibers can also be varied regionally usingfibers containing varying amounts of anti-microbial agents inconjunction with both natural and synthetic fibers having differentamounts of anti-microbial agents or even no added anti-microbial agents.A variety of other agents can be added, either by mixing or topically,to color the fibers and/or to make it resistant to stains, fire, andultraviolet (UV) light, as well as altering its water absorbingqualities. Various polymers, can be used to form these fibers. In thecontext of this invention, anti-microbial refers, but is not limited, tohaving anti-bacterial and anti-fungal properties.

[0168] It is the object of the present medical wipes embodiment toprovide medical and health care wipes that meet these needs withattendant durability in a cost-effective manner.

[0169] It is another object of the present embodiment to provide medicaland health care wipes that which have anti-microbial properties andwhich will not be abraded away by use.

[0170] The foregoing objects are met by medical wipes basedanti-microbial fibers that have been designed using inorganicsilver-containing compounds that allow the formation of both mono- andmulti-component polymeric fibers having these anti-microbial agentsintermixed within the polymer during fiber formation.

[0171] Medical or health care wipes of the present embodiment have avariety of purposes. One is to absorb fluid or semi-fluid bodysubstances such as blood. Another is to provide a liquid or semi-liquidfor cleaning and/or disinfecting an area of the body. A further one isto disinfect or clean instruments of various types which are used in themedical field in and around the human body. The actual construction ofsuch wipes differ depending upon the intended use.

[0172] However, there are some similarities in many such wipes. They aremade from non-woven materials and have an active surface which is liquidpermeable, a thicker under layer of an absorbent material, and an upperlayer of liquid impervious material so that a user of such a wipe willnot have the liquid touch the users fingers, which are thus protected.For convenience some types will have a handle. If the wipe is to absorbliquid materials, the absorbent material will be dry. However, if thewipe is used for cleaning purposes, the absorbent material will usuallybe the reservoir for the liquid or semi-liquid cleaning material.

[0173] In each type of wipe, at least the surface of non-woven materialwhich engages the skin or material to be cleansed is provided withanti-microbial properties as described herein. That is an inorganicanti-microbial agent is incorporated into the outer surface layers ofits fibers to provide anti-microbial properties thereto.

[0174] The concentration of the anti-microbial agent can be variedwithin each individual fiber as a gradient using mixing strategies andalso from fiber to fiber. The concentration of anti-microbial agentwithin a fabric or material made from these anti-microbial fibers canalso be varied regionally using fibers containing varying amounts ofanti-microbial agents in conjunction with both natural and syntheticfibers having different amounts of anti-microbial agents. A variety ofother agents can be added, either by mixing or topically, for differentreasons, such as altering its water absorbing qualities. Variouspolymers can be used to form these fibers. In the context of thisinvention, anti-microbial refers, but is not limited, to anti-bacterialand anti-fungal.

[0175] The invention uses fibers with silver zeolite as a component in amedical wipe cloth. The finished product may be constructed ofnon-woven, knit, woven or other material. It may also be treated orpre-moistened with a topical treatment such as a soap solution or otheradditive. The finished product may be produced from any combination ofnatural or synthetic fibers in addition to the anti-microbial fibers. Awipe cloth may be unitary or combined or laminated to some other fabric.

[0176] The purpose of this invention is to help prevent the growth andspread of microbes/bacteria when a wash cloth or wipe comes in contactwith the human body. Without the anti-microbial treatment, the washcloth or wipe merely spreads bacteria. With the anti-microbialtreatment, it is believed that bacteria are killed from contact with theanti-microbial treated wash cloth or wipe.

[0177] Many current wipe cloths used in food service or the home collectbits of organic matter which does not fully rinse out. This matterbecomes a food source for the growth of bacteria and mold.

[0178] This invention incorporates an anti-microbial additive, e.g.zeolite of silver, in fiber used to make wipes for food service.

[0179] The healthcare wipe currently has preservatives added to theliquid in the packages so that the wet wipe will not contain bacteria ormold. Preservatives by their nature can cause allergic reactions whenthey come in contact with the skin.

BRIEF DESCRIPTION OF THE DRAWING

[0180] Other objects, features and advantages will be apparent from thefollowing detailed description of preferred embodiments taken inconjunction with the accompanying drawings in which:

[0181]FIGS. 1A, 1B, 1B′, 1B″ and 1C are cross-sectional views of variousfiber configurations used in practice of the various embodiments of theinvention;

[0182]FIG. 2 is a sketch of a fibrous mass using one or more of thefibers of FIGS. 1A-1C;

[0183]FIG. 3 is a schematic view of the feed hopper, screw and extruder;

[0184]FIG. 4 is a sectional view through the exit of the extrudershowing the formation of coaxial bi-component fibers of the presentinvention;

[0185]FIGS. 5 and 6 are photomicrographs of fibers showing the particlesof zeolite of silver;

[0186]FIG. 7 shows a garment made from the fibers of the presentinvention for a person who is incontinent;

[0187]FIG. 8 is a cross section of one type of filter using the fibersof the present invention;

[0188]FIGS. 9A, 9B, 9C, 9D are diagrams of air flow systems utilizingthe fibers of the invention;

[0189]FIG. 10 is a cross section of one type of wound care or burndressing;

[0190]FIG. 11 is a flow chart showing the preparation of the fibers andyarn for use in making a woven or nonwoven fabric;

[0191]FIG. 12 is a flow chart showing the preparation of fibers and yarnand then of a fabric;

[0192]FIG. 13 is a flow chart showing another manner of preparing fibersin accordance with the present invention;

[0193]FIG. 14 is a schematic isometric view of a first type of insoleusing latex;

[0194]FIG. 15 is a schematic isometric view of a second type of insoleusing a layer of anti-microbial fibers;

[0195]FIG. 16 is a side view of a sheet material having ananti-microbial film layer co-extruded thereon;

[0196]FIG. 17 is a side view of a sheet material having twoanti-microbial films extruded thereon, one on each side;

[0197]FIG. 18 is a side view of a further arrangement in which a doublesheet material is complete surrounded by an anti-microbial film;

[0198]FIG. 19 is a side view of a shaped sheet material having twoanti-microbial films extruded thereon;

[0199]FIG. 20 is an isometric view of a food tray constructed inaccordance with the present invention;

[0200]FIG. 21 is a partial sectional view of apparatus for making amulti-layer co-extruded sheet;

[0201]FIG. 22 is a sectional view through the apparatus shown in FIG.21;

[0202]FIG. 23 is an isometric view of apparatus for making aside-by-side co-extruded sheet;

[0203]FIG. 24 is a cross section through an insole made in accordancewith the present invention;

[0204]FIG. 25 is a plan view of the insole of FIG. 24;

[0205]FIG. 26 is a cross section through a laminate for footwearcomponents;

[0206]FIG. 27 is a cross-sectional exploded view through an officepartition;

[0207]FIG. 28 is a schematic view of a humidifier evaporation surfacemedia used to humidify air;

[0208]FIG. 29 is a schematic view of a humidifier pad or filter in asystem; and

[0209]FIG. 28 is a pad or filter for a circulation/aeration system.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0210] In the United States, all claims concerning anti-microbial andanti-fungal properties must be thoroughly tested to EnvironmentalProtection Agency (EPA) and Food and Drug Administration (FDA) standardsbefore making claims. The anti-microbial herein can be said to “killbacteria” in that it kills 99.99% (log 4) of bacteria in 24 hours, and“anti-microbial” in that is kills 99.9% (log 3) of bacteria in 24 hours.This is based upon actual test results. Testing, such as by using theshake flask test, has demonstrated that when fibers and fabrics aretested using the anti-microbial system disclosed herein, the number ofbacteria on the fibers is reduced by 99.99% or more over a 24-hourperiod and at least by 99.9%. This testing was performed using severaldifferent bacteria, including Pseudomonas aeruginosa, Staphylococcusaereus and Klebsiella pneumoniae. The testing was conducted using bothunwashed fibers and fibers that had been washed fifty times to simulateuse of the fiber in an application, such as a pillow. The EPA hasindicated that products tested using this system may claim “ProhibitsBacteria Growth and Migration Along the Surface of the Product.” Theaddition of the agent in this system inhibits the growth of mold andmildew or odor-causing bacteria in the fibers. This is a trueanti-microbial product. The fibers retain their efficacy after simulateduse conditions so that the anti-microbial action lasts the life of theproduct.

[0211] The Fibers and the Additives

[0212] According to a first configuration of the present invention shownin FIGS. 1A-2a bi-component fiber 10A is formed of a sheath component Sand a core component C using polyethylene terephthalate (PET) (or otherthermoplastic polymer) in the core, making up between 20 to 80% of thefiber by weight. The sheath is also PET, or other thermoplastic polymer,making up between 80 to 20% of the fiber by weight including, as adispersed solid, additive A (or compounded with the sheath plastic) ananti-microbial compound, to gain the efficiency of the additive on thesurface and not wasting the additive in the core.

[0213] In the more generalized case as mentioned above, the sheath maybe quite thin. However, preferably the sheath is more than 28% of thetotal fiber cross-section. It has been found that one of the bestmethods for retaining the anti-microbial qualities in the fiber and infabrics is to use sheath thicknesses which are properly related to thesize of the anti-microbial additive particles. For example, when theanti-microbial particles are approximately 1 micron cubes, whichprovides diagonal dimensions of approximately 1.7 microns, the sheaththickness would be in the vicinity of 2 microns. In this manner theparticles of the agent are firmly held in the sheath by the material ofthe sheath holding them in place. When the particles are larger orsmaller, the thickness of the sheath is adjusted accordingly.

[0214] The anti-microbial anti-fungal additives are inorganic compoundsusing such metals as: copper, zinc, tin, and silver. The best resultsare obtained using a zeolite of silver dispersed in a polyethylene (PE),PET, or polybutylene terephthalate (PBT) carrier, but could be addeddirectly to a melt of a sheath thermoplastic without an intermediatecarrier. The total anti-microbial additive ranges from 0.2% (0.002) to6.0% (0.06) by weight of fiber depending on performance requirements.The anti-microbial additives are held in the sheath and are preventedfrom washing off over time and remain effective, especially when thesheath-thickness to agent-particle size ratio is in a desirable range asmentioned above and discussed in more detail below.

[0215] The bi-component anti-microbial/anti-fungal synthetic fiber sizewould preferably range from 0.7 dTex to 25.0 dTex and could be producedas a cut staple fiber in lengths from 1.0 mm to 180 mm, or in acontinuous filament.

[0216] Additives which can be incorporated include one or more of UVstabilizers at 0.1% (all %'s herein are by weight unless otherwisestated) to 5.0%; fire retardant (FR) additives at 0.1% to 5.0%; pigmentsat 0.1% to 6.0%; hydrophilic additives at 0.2% to 5.0%; hydrophobicadditives at 0.2% to 5.0%; and/or anti-stain additives at 0.2% to 5.0%.

[0217] A second configuration of this first embodiment of the presentinvention is a bi-component fiber 10B in which the components x, y(x=strength, y=functional portion) are side-by-side and the samepolymers and additives are used as described above. Variants of this areshown in FIG. 1B′ in which the tri-component fiber 10B′ has componentsx1, x2 and y′, and in FIG. 1B″ in which the four-component fiber 10B″hascomponents x1, x2, y1 and y2.

[0218] A third configuration shown in FIG. 1C is a continuous filament10C that could be used by itself as the binder or as part of a yarn orfabric with cooperating (strength) fibers indicated at 10D.

[0219] It should be understood that the nominal “binder” fiber or bindercomponent can also be a strength enhancer in some combinations. It willalso be understood that other variants with respect to FIGS. 1A-1C,including, but not limited to combinations, can be made. For example, afirst extrusion could produce intermediate fiber products as in FIG. 1Aand such products could be put together with each other or separatestrength fibers and processed to produce simulations of FIGS. 1B, 1B′.1B″, 1C.

[0220]FIG. 2 shows a non-woven or woven fibrous mass M made up of any ofthe fibrous configurations of FIGS. 1A-1C after heating wherein thebinder fiber component melts and flows to form locking knots at many (ifnot most or all) of the cross-over points or nodes N of the fibrous massto enhance strength and durability of the mass while maintaining adispersion of the binder materials and its functional additive(s).

[0221] While the preferred embodiment is a PET/PET bi-component withzeolite of silver being used only in the sheath. Resins with differentviscosities can be used to obtain improved performance. A PCT/PETarrangement is one variation which takes advantage of the hydrolysisresistance and resilience; however, the PET/PET is more cost effective,especially for use in apparel and bedding.

[0222]FIGS. 1A-2 can also be used to describe a second embodimentgrouping of practice of the invention.

[0223] The first configuration of the second embodiment of the presentinvention is a bi-component fiber of a core and a sheath as shown inFIG. 1A using PET or other high tenacity polymer in the core at between20% and 80% by weight of the fiber. Poly 1,4 cyclohexylene dimethyleneterephthalate (PCT) or other hydrolysis resistant polymer is used forthe sheath at 80% to 20%. The core is designed to provide the strengthof the fiber and the modulus can be varied to create a high modulusfiber with properties of high tenacity and low elongation similar tocotton, or a low tenacity and higher elongation fiber with propertiessimilar to wool; or anywhere in between to obtain different fibers tomake them as compatible as possible for their end uses and for any blendin which they will be used. In fibers, modulus refers to the area underthe curve in a stress/strain curve. The sheath is preferably over 28% ofthe total cross sectional area. The sheath uses PCT which provides ahydrolysis resistant surface with good wrinkle resistance and resistanceto long term washings in boiling water and strong soaps.

[0224] Additives in this second embodiment include pigments, compoundsto create a hydrophilic surface, and anti-microbial, anti-fungal,anti-odor additives. The pigment additives are to provide uniform colorsthat do not fade significantly over long-term use and washing, unlikedyes. Compounds may be used which create a hydrophilic surface and thisis designed to wick body moisture away from the skin and evaporate tocreate comfort for a wearer of a garment containing such fibers and isparticularly useful for career apparel such as uniforms, work clothes,etc. The anti-microbial, anti-fungus and anti-odor additives can bevaried depending on the functionality of the career apparel.

[0225] The bi-component anti-microbial/anti-fungal synthetic fiber sizeranges from 0.7 dTex to 25.0 dTex and can be produced as a cut staplefiber in lengths from 1.0 mm to 180 mm, or in a continuous filament.

[0226] Another arrangement (FIG. 1C) is a bi-component continuousfilament that could be used by itself or as part of a yarn or fabric.

[0227]FIGS. 1A-2 can also be used to describe a third embodimentgrouping of practice of the invention.

[0228] The third embodiment of the invention is a mono-component ofhomo-polymer fiber made from low temperature polymers with a melting orsoftening temperature below 225° C. such as PETG. It relates to a binderfiber carrier for anti-microbial additives, which can be further blendedwith non-anti-microbial fibers to provide an anti-microbial finishedfabric that is able to withstand significant wear and washings andmaintain their effectiveness. The anti-microbial additives areinorganic.

[0229] A mono-component or homo-polymer fiber used in this embodimentwas made from low temperature polymers with a melting or softeningtemperature below 225° C. such as PETG (PET modified with 1,4,cyclohexanedimthanol), PE, PP, co-PET, or amorphous PET. Another lowmelting temperature polymer which may be used is polycaprolactam (PCL).The anti-microbial additives are inorganic compounds made from metalssuch as copper, tin, zinc, silver, etc. The preferred compound is azeolite of silver dispersed in PE, PET, or PBT before being added to thefiber. The additives could be added directly to the primary polymer withpre-dispersion. The total active ingredients range from 0.1 to 20% byfiber weight. Other inorganic metals such as tin, copper, zinc, etc.work also but not as well as zeolite of silver.

[0230] The binder (carrier) fiber containing polymers and anti-microbialadditives can be blended with non anti-microbial natural fibers such ascotton and wool, or synthetic fibers such as polyester, acrylic, nylon,PTT, 3GT, rayon, modified rayon, and acetate to an anti-microbialfinished fabrics that is able to withstand significant wear and washingsand maintain their effectiveness.

[0231] A typical example is a fiber using the PETG polymer with thezeolitic contained silver additive blended with cotton up to 10% byweight to produce a bed sheet. The binder fiber is activated in thedrying cycle of the final bleaching operation or other heat operation.The PETG melts and wets the surface of the cotton fibers to carry theanti-microbial characteristics to the entire sheet with an added benefitof increasing strength and reducing pilling.

[0232] The fiber size ranges from 0.7 dTex to 25 dTex and a staplelength of 1.0 mm to 180 mm. A continuous filament yarn can also beproduced that can be used in a wrap spun application wherebynon-anti-microbial fibers are spun around the anti-microbial filament.

[0233] The antimicrobial product withstands more than 50 commercialwashings at 80° C. and/or dry cleanings. It is immune to UV exposure ofat least 225 kj. It possesses excellent abrasion resistance and isunaffected by tests such as Tabor or Wyzenbeek.

[0234] The present invention also provides a unique way to use polymerssuch as PETG to carry and deliver anti-microbial additives and/orpigments to a natural non-anti-microbial fiber, such as cotton, wool,possibly mixed with polyester, nylon and the like, and generate a finalbinding fabric having anti-microbial properties.

[0235] PETG has two characteristics of interest: (1) excellent wettingand (2) low melting temperature. In the present invention, it is used asa carrier to carry anti-microbial additives and be blended withnon-anti-microbial fibers. After heat activation, the PETG melts,continuously releases the anti-microbial additives and wets the surfaceof the surrounding non anti-microbial fibers with the anti-microbialadditives it carries. Thus, PETG delivers and distributes theanti-microbial additive uniformly within a fabric and the PETG holds theanti-microbial agent in place, generating the finished fabrics havinganti-microbial property. Since the natural fibers used to blend withPETG are not changed physically in this process, they contain the samecharacteristics as natural fibers.

[0236] The bi-component fiber may be formed by the use of pellets of thetwo different polymers or a direct polymer stream from the reactor ofwhich the fiber is to be formed. The arrangement shown in FIG. 1A isintended for a configuration of a core fiber, and a sheath fiber whichcontains an additive, e.g., an anti-microbial agent. Since the best ofthe anti-microbial agents known at this time to the present inventor iszeolite of silver, the present example uses this agent. The intent is touse the minimum amount necessary to provide the desired characteristics.The additive provides the desired anti-microbial effect only at thesurface. Therefore, if the bulk of the additive is located within thevolume of the fiber well below the surface, that portion will not beuseful for most or all of the life of the material into which the fiberis made. Since there frequently is some surface abrasion, some of theadditive particles which are just below the surface when the fiber ismade, become available at the surface, later in the life of the product.

[0237] In the past, attempts have been made to provide the additive atthe surface, and the result was that the additive particles did not havea very useful life since they were removed from the surface by washingand wear or use. Therefore, the present invention strongly attaches theadditive particles to the outer region of the fiber.

[0238] It has been possible to make particles of zeolite of silver assmall as 1 micron cubes. A particle of such size will have a diagonaldimension of about 1.7 micron. Therefore, the smallest thickness of thesheath would be about 2 microns. The present invention permits acore/sheath arrangement in which the sheath is as small as 2 microns inthickness with the additive incorporated into the sheath. The diameterof the sheath is adjusted to the particle size so that the particles areheld firmly in place and are available at the surface of the sheath. Theparticles may be smaller or larger than 1 micron cubes or larger, andthe sheath may be correspondingly smaller than 2 microns or larger. Insuch an arrangement most, or all, of the additive is available forsurface action, and, with wear and/or washings a small amount of thesurface of the sheath will wear or wash away, and other additiveparticles which were originally more deeply embedded, become availableat the surface.

[0239] The photomicrographs of FIGS. 5 and 6 show the small particles ofzeolite of silver in the sheath, many of which can be seen on thesurface or projecting through to the surface of the fibers. There aremore such particles which are just below the surface of the fibers, andwhich will become available for anti-microbial activity as smallportions of the fiber wears or washes away and the particles becomeavailable at the surface.

[0240]FIGS. 3 and 4 show a manner of making a core/sheath fiber with ananti-microbial additive which is incorporated into the sheath polymerprior to the final extruding of the fiber. In the prior art, this wasmostly done as a treatment after extruding.

[0241] The extruder 12 is shown diagrammatically in FIG. 3 having a feedhopper 14, an extruder screw section 16 for feeding melted material tothe delivery end, and a heating chamber 18 which surrounds the bottom ofthe feed hopper as well as the total length of the extruder screwsection 16 for melting the pellets which are fed into the hopper andmaintaining the polymers in melted condition for being extruding throughthe extruding openings which act as nozzles. Besides pellets, it ispossible to make these fibers using direct polymer streams fromcontinuous reactors feeding to the melt pumps for a company which is apolymer producer.

[0242] There are two extruders, one which has a feed hopper for formingthe sheath and another with a hopper for forming the core.

[0243] The nozzle end of the extruder is shown in cross section in FIG.4 which includes three sheets of metal 20, 22 and 24 to form twochambers 26 and 28. The melted polymer is fed into the extruder nozzlefrom the top. There are a plurality of two types of holes, one typebeing 28 and which feeds into chamber 26 to form the core of the fiber,and the other type being 32 which feeds into chamber 28 to form thesheath of the fiber.

[0244] The following non-limiting examples illustrate practice of theinvention.

EXAMPLE 1

[0245] The anti-microbial fiber of the present invention was used in themaking of a mattress pad. In this example, 15% of a 6.7 denier 76 mm cutlength natural white fiber was used as a homofilament with zeolite ofsilver as the anti-microbial agent and 15% of a bi-component fiber wasused together with 70% PET 6×3 T295 in a blend in which the zeolite ofsilver comprised 0.9% of the fiber. The blend of this fiber was madeinto a batt of about 1-1½″ thickness of nonwoven material which was thenplaced between two layers of woven fabric to form a mattress pad. Whentested using the shake flask test this provided a 99.99% microbial killratio.

[0246] There are other examples in which all of the parameters ofExample 1 were used and in each of which there was 15% of a bi-componentfiber used. Again the zeolite of silver comprised 0.9% of the fiber. Thepercentage of the anti-microbial fiber ranged from 20% to 40% and thePET ranged from 45% to 65%. In all examples the microbial kill ratio was99.99% using the shake flask test.

EXAMPLE 1A

[0247] In this example, 35% of a 6.7 denier 51 mm cut length naturalwhite fiber was used in a sheath/core bi-component configuration withzeolite of silver as the anti-microbial agent and 15% of anotherbi-component fiber was used together with 50% PET 6×3 T295 in a blend inwhich the zeolite of silver comprised 1.8% of the fiber. The blend wasthen prepared as in Example 1 and when tested using the shake flasktest, there was a 99.9% microbial kill ratio.

[0248] A second group similar to the first one was prepared in which thesheath/core bi-component fiber with zeolite of silver as theanti-microbial agent comprised from 10 to 35% of the fiber blend, 15% ofanother bi-component fiber was used and from 50 to 75% of PET 6×3 T295was used. The zeolite of silver comprised 0.75% of the fiber. In theshake flask test, there was a 99.99% microbial kill ratio.

EXAMPLE 2

[0249] In this example, 15% of a 3.5 denier 38 mm cut length PETG fiberwas used as a homofilament with zeolite of silver as the anti-microbialagent. 85% PET fiber was blended with the PETG anti-microbial fiber toform a blend in which the zeolite of silver comprised 1.8% of the fiber.The fiber was made into a wall covering and was tested by the shakeflask test, which provided a microbial kill rate of 99.99%

[0250] A modified version was prepared the same way except that therewas only 10% fiber with zeolite of silver in the blend and 90% PET fiberwas used. After the fiber was made into a wall covering, this tooprovided a 99.99% microbial kill rate using the shake flask method oftesting.

[0251] A further modified version was used in which there was only 5%fiber having zeolite of silver in the blend and 95% PET fiber in theblend. The testing, after the fiber was used in a wall covering, againprovided a 99.99% microbial kill rate for bacteria.

[0252] The fibers described above can be used to make both woven andnonwoven fabrics as well as knitted fabrics. Such fabrics are useful forvarious types of articles, some of which are listed below.

[0253] Incontinent Garments

[0254] Incontinent garments, including disposable diapers, underwear,pajamas, and linens, some of which may be knitted. This is disclosed,for example, in pending provisional application Serial No. 60/173,207filed Dec. 27, 1999, the contents of which are physically incorporatedherein below, in which garments and other articles for incontinentpersons made of an anti-microbial fiber comprises various thermoplasticpolymers and additives in a mono-component or bi-component form ineither a core-sheath or side-by-side configurations. The anti-microbialsynthetic fibers can comprise inorganic anti-microbial additives,distributed only in certain areas in order to reduce the amount of theanti-microbial agents being used, and therefore the cost of such fibers.The anti-microbial additives used in the synthetic fibers do not washoff over time because they are integrally incorporated into thesefibers, thus their effectiveness is increased and prolonged. Theanti-microbial synthetic fibers comprise high tenacity polymers (e.g.PET) in one component and hydrolysis resistance polymers (e.g. PCT) inanother component. The hydrophilic and anti-microbial additives providea hydrolysis-resistant surface with good wrinkle resistance that resultsin long-term protection against washings in boiling water and strongsoaps. The anti-microbial synthetic fibers can further be blended withnon-anti-microbial fibers such as cotton, wool, polyester, acrylic,nylon etc. to provide anti-microbial finished fabrics that are able towithstand significant wear and washings and while maintaining theireffectiveness.

[0255] Anti-microbial fibers can be used to make materials for a varietyof applications in which it is necessary or desirable to reducebacterial and fungal growth and the resultant odor. Specifically, inpersonal hygiene situations, these materials can be used in reusable orre-wearable incontinent garments and other articles such as linens andbed packs to prevent bed sores on persons confined to bed for extendedperiods of time. Diapers and other clothing and articles for incontinentindividuals are constantly and intermittently being soaked with urineand these items as now manufactured are not effective at killing odorand infection-causing bacteria. By making these items disposable, thegrowth of bacteria and fungi is reduced depending upon how often theyare changed, but there are environmental and other considerations todisposables. However, the use of the anti-microbial fibers in suchgarments and articles that maintain their effectiveness during washings,results in reusable garments and articles of the type described withodor reducing and anti-microbial properties which last for the life ofsuch garments and articles.

[0256] As a result of the above, the use of anti-microbial fibers in themanufacture of incontinent garments is desirable. These anti-microbialfiber-containing garments are useful in reducing the growth of bacteria,fungi, and other microbes once soaked with urine, thus reducing thediscomfort of the individual and preventing infections generally.Specifically, the anti-microbial fiber-containing fabrics may be used inboth the covering fabric and the water absorbent interior material. Inthis way, both surface and interior protection is achieved. In addition,these materials may also be made to be reusable because theanti-microbial effect of the fibers of these garments and articles areresistant to multiple washings. Thus, a significant cost savings isrealized in the laundry operations of hospitals and nursing homes aswell as in the economics of individual households.

[0257] In manufacturing these materials, any of the fiber embodimentsdescribed below could be used. Both the strength and resiliency of thesematerials is important since they must stand up to multiple wettings andsubsequent cleanings. Thus, both bi-component fibers and mixed fiberfabrics are useful embodiments for incontinent garments. Also, othermodifications of the characteristics of these fibers and fabrics beyondthat of adding anti-microbial agents, including the addition of agentsto increase or decrease hydrophobicity, are useful in view of therepeated wettings and the need for frequent cleanings and washings. Inaddition, anti-odor additives may be particularly useful in thisapplication in light of this frequency of cleaning, as well as thewetting with urine. Thus, these anti-microbial materials, garments andarticles significantly reduce the growth of mold, mildew, and bacteriain home and institutional environments.

[0258] Garments for incontinent persons are made of anti-microbialfibers designed to use inorganic silver-containing compounds that areintegrated into the polymers that are used to make these anti-microbialfibers. However, other metals (such as copper, potassium, magnesium, andcalcium) can be used as anti-microbial agents. In addition, mixtures ofdifferent metal-containing anti-microbial agents in differingconcentrations can be used that result in hybrid agents tailored forspecific tasks.

[0259] Such garments may be knitted or woven and include underwear,pajamas, linens, disposable diapers, and the like.

[0260] One type of such garment of the present invention is shown inFIG. 7 in which there is a garment 34 which carries a removable linerassembly 36 which is detachably secured within the garment. The linerassembly includes an outer layer 33 which contacts the skin of a wearer44 around the buttocks and crotch area. This layer is made to be smoothand soft so as to be comfortable for the wearer even when fluids such asurine contact this layer and pass therethrough. There is a wick layer 35which changes color when it is wet so that attendants can see from adistance that a wearer is wet and needs to receive some attention, suchas the changing of the liner assembly. Beyond the layer 35 is anabsorbent layer 31 formed of a mass of fibers. There is an inner layer37 which is impervious to fluids so that the fluids such as urine do notwet and/or stain the outer layer of clothing. The liner assembly 36 isheld together by soft fiber connectors 38. The liner itself may beremovably attached to the basic garment with Velcro so that it is easilyremovable and changed.

[0261] The liners 36 may be constructed to be washable so that they canbe reused, or can be made to be disposable. The garment has a belt 42for holding the garment in place.

[0262] The outer layer 33 is made of anti-microbial fiber of the typedescribed in further detail below so that there is protection frommicrobes and fungus which causes infection and odors.

[0263] Layer 33 is made to be a porous fiber material which will drawany moisture from the wearer by wick action away from the wearer's skinand into the absorbent liner. Since the layer 33 is always against thewearer's skin and at least at times is wet from urine, there is the riskof infection which, with the present invention is prevented, due to thelayer 33 being constructed of anti-microbial fibers, the construction ofwhich is described in more detail above.

[0264] The absorbent material 31 of the liner 36 may also be made ofnon-woven fibrous material which is also anti-microbial if desired.

[0265] Anti-microbial fibers may be made into other products intendedfor incontinent persons, such as bed linens, and bed packs which areused to prevent bed sores in persons who are confined to bed forextended periods of time. Such products provide a first line of attackagainst problems caused by microbes especially when used in all areas ofthe products which come into contact with a person's skin.

[0266] Higher loading of the anti-microbial agents (up to 5 times) isused to more effectively act against fungi. This higher loading may beachieved by using various zeolites followed by heating the fiberpolymer, e.g. PET, to between 180 and 228 degrees Fahrenheit in hotwater which allows further metal loading or ion exchange to replaceresident metal ions with another ion or mixture of ions. In addition,this would allow the zeolite at or near the surface of the fiber to bepreferentially loaded with the metal ion or mixtures thereof that hasthe desired biological effect. These methods are particularly useful inreducing costs when expensive metal ions, such as silver, are used inthese processes. Also, by adding certain metals, e.g. silver, at thispoint in the process and not having it present during the hightemperature fiber extrusion process, any yellowing or discoloration dueto oxidation of the metal ion or its exposure to sulfur and halogenswould be greatly reduced.

[0267] Air Filters

[0268] Air filters for HVAC systems, air conditioning systems, car andairplane cabin systems as disclosed, for example, in Serial No.60/172,285 filed Dec. 17, 1999, the contents of which are incorporatedherein below, in which filters and filter materials are made ofanti-microbial fibers for a variety of filter applications in which itis necessary or desirable to reduce bacterial and fungal growth andtheir resultant odor. Specifically, in vehicles, such as automobiles,the air filters and attached air conditioning units are the source ofmusty smells associated with the seeding and growth of bacteria, fungi,mold, and mildew. Because of the recirculation of outside andair-conditioned air through these filters, very favorable conditionsexist for the growth of bacteria, fungi, and other microbes. Also inaircraft cabins, the air filters have the same beneficial results. Ananti-microbial filter is made of fiber, which comprises variousthermoplastic polymers and additives in a mono-component or bi-componentform in either a core-sheath or side-by-side configurations. Theanti-microbial synthetic fibers can comprise inorganic anti-microbialadditives, distributed only in certain areas in order to reduce theamount of the anti-microbial agents being used, and therefore the costof such fibers. The anti-microbial additives used in the syntheticfibers do not wash off over time because they are integrallyincorporated into these fibers, thus their effectiveness is increasedand prolonged. The anti-microbial synthetic fibers comprise hightenacity polymers (e.g. PET) in one component and hydrolysis resistancepolymers (e.g. PCT) in another component. The hydrophilic andanti-microbial additives provide a hydrolysis-resistant surface. Theanti-microbial synthetic fibers can further be blended withnon-anti-microbial fibers such as cotton, wool, polyester, acrylic,nylon etc. to provide anti-microbial finished filters that are able towithstand significant wear and washings and while maintaining theireffectiveness.

[0269] The present invention provides filters based on anti-microbialfibers that have been designed using inorganic silver-containingcompounds that allow the formation of both mono- and multi-componentpolymeric fibers having these anti-microbial agents intermixed withinthe polymer during fiber formation. The concentration of theanti-microbial agent can be varied within each individual fiber as agradient using mixing strategies and also from fiber to fiber. Theconcentration of anti-microbial agent within a fabric or material madefrom these anti-microbial fibers can also be varied regionally usingfibers containing varying amounts of anti-microbial agents inconjunction with both natural and synthetic fibers having differentamounts of anti-microbial agents or even no added anti-microbial agents.A variety of other agents can be added, either by mixing or topically,to color the fibers and/or to make it resistant to staining, fire, andultraviolet (UV) light as well as altering its water absorbingqualities. Various polymers, without limitation, can be used to formthese fibers. In the context of this invention, anti-microbial refers,but is not limited, to antibacterial and anti-fungal.

[0270] The amount of time people spend in their vehicles has beenincreasing over the last 20 years. The passenger compartment of thesevehicles is an extension of people's personal space. The desired qualityof the air in that space increasingly reflects peoples' desire to beprotected from airborne particles and odors, and bacteria. Such vehiclesinclude pick-up trucks, SUVs, recreational vehicles, buses,over-the-road trucks, and the like.

[0271] Anti-microbial fibers can be used to make filter materials for avariety of applications in which it is necessary or desirable to reducebacterial and fungal growth and their resultant odor.

[0272] Specifically, the built in or attached air conditioning units forover the road vehicles are a source of musty smells associated with theseeding and growth of bacteria, fungi, mold, and mildew on theevaporator and or heater cores and housings. These areas, by theirnature, collect dust, dirt, bacteria, mold spores, etc. in anenvironment that contains the moisture, temperature, and shielding fromdirect sunlight necessary to promote growth of these organisms.

[0273] A filter containing permanent anti-microbial fibers, describedherein, could be placed in the outside make-up air and/or recirculatedair streams to kill the spores and cells trapped by the filter. Thiswould reduce or eliminate the odors associated with growing andreproducing organism.

[0274] The permanent nature of the anti-microbial fibers in the filteris necessary based on the environment of operation and desiredreplacement life. The filters are subjected to moisture from entrainedwater from the blower fan inlet (rain, or wash water) as well ascondensation of moisture when the air conditioning system is inoperation. Further, the vehicle owners, and vehicle design engineers,want a filter that has at least a one year life. Both conditions can beovercome with permanently anti-microbial fibers described herein.

[0275] Such anti-microbial fiber-containing filters are useful inreducing the build-up of biological materials and films on the filtersthemselves and the associated air conditioning units. Thus, they wouldalso be less likely to impart undesirable odors to the interior of thevehicles.

[0276] In manufacturing these materials, any of the embodimentsdescribed above could be used. Both the strength and resiliency of thesematerials is important given that they are used in continuouslycirculating air streams and are subject to the pressures characteristicof filtering processes. Any number of filter shape designs could be usedas appropriate. In some instances, round filters would be appropriatewhereas in other instances pleated or other shape filters would beappropriate, all depending on the pressure, volume characteristics ofthe air flow and available space. Thus, both bi-component fibers andmixed fiber fabrics are useful embodiments for vehicle and aircraftcabin air filters. Also, other modifications of the characteristics ofthese fibers and fabrics beyond that of adding anti-microbial agents,including the addition of agents to increase or decrease hydrophobicity,would be useful. In addition, anti-odor additives may be particularlyuseful in this application given the use in connection with airconditioners.

[0277] Thus, these anti-microbial materials that are manufactured to beused in vehicle and aircraft cabin air filters will then significantlyreduce the growth of mold, mildew, and bacteria. By achieving this goal,odors associated with the long-term use of these filter materials willbe reduced. This will also then result in a significant costs savings inthe operation of air recirculation systems in automobiles.

[0278] Filters for vehicle and aircraft cabins are, according to theinvention, made of anti-microbial fibers which use inorganicsilver-containing compounds that are integrated into the polymers thatare used to make these anti-microbial fibers. Such a filter is showndiagrammatically in FIG. 8. The example shown in a typical progressivefilter which has three layers. There is a support layer 44, then afiltration layer 42 made with anti-microbial fibers and then a prefilterlayer 40 also made with anti-microbial fibers.

[0279] The relatively small size of the silver-containing zeolitecompounds (2 microns and less) that are used in the manufacturing of thefibers allow these anti-microbial agents to be incorporated into fibersinstead of being applied to them. For example, a bi-component fiber ismade with the sheath having a thickness which is properly related to thecubic size of the zeolite particles. Zeolite particles have a one microncube size would be placed into a sheath having a two micron thickness.Thus, because these anti-microbial agents are an integral part of thefiber, they are not washed or easily abraded away and the finishedarticles, in the present case, filters, manufactured from them are ableto withstand significant wear and multiple washings while maintainingtheir anti-microbial effectiveness (for those filters which are washed).In the case of filters which are thrown away when they start to becomeclogged with filtered material (air borne particles and the like) theresistance to washings is not an important factor.

[0280]FIG. 9A shows a system of filter usage for an occupancy zone whereair is removed via valve V1 through a pump or compressor P passedthrough a filter canister F (or other container) and a heating orcooling exchanger (HVAC) and returned to the occupancy zone via valveV2. The system can also handle outside air via a valve V3.

[0281] The canister has a removable anti-microbial filter screen F (witha frame, not shown) removable for exchange or regeneration ofanti-microbial effectiveness from time to time.

[0282] Another form of filter is shown in FIG. 9B as filter canister FC′with vanes V defining a tortuous path, the vanes being lined withanti-microbial screening material F′

[0283]FIG. 9C shows another form of canister as a tube FC″ lined withsuch filter material F″ and FIG. 9D shows a canister FC′″ with a loosearray of filter material F′″ (similar to a scouring pad).

[0284] Wound Care Dressings and Burn Dressings

[0285] Wound care dressings and burn dressings made of fibers asdisclosed, for example, in Serial No. 60/172,533 filed Dec. 17, 1999,the contents of which are physically incorporated herein below in whichan anti-microbial wound care dressing or burn dressing is made of fibersuch as various thermoplastic polymers and additives in a mono-componentor bi-component form in either a core-sheath or side-by-sideconfigurations. The anti-microbial synthetic fibers can compriseinorganic anti-microbial additives, distributed only in certain areas inorder to reduce the amount of the anti-microbial agents being used, andtherefore the cost of such fibers. The anti-microbial additives used inthe synthetic fibers do not wash off over time because they areintegrally incorporated into these fibers, thus their effectiveness isincreased and prolonged. The anti-microbial synthetic fibers comprisehigh tenacity polymers (e.g. PET) in one component and a hydrolysisresistance polymer, PCT, in another component. The hydrophilic andanti-microbial additives provide a hydrolysis-resistant surface withgood abrasion resistance. The anti-microbial synthetic fibers canfurther be blended with non-anti-microbial fibers such as cotton, wool,polyester, acrylic, nylon etc. to provide anti-microbial finished woundcare dressings and burn dressings that are able to withstand significantwear and any washings they may be given (if the washable type) and whilemaintaining their effectiveness.

[0286] Wound care dressings may be made with anti-microbial fibers usedto make various materials for a variety of applications in which it isnecessary or desirable to reduce bacterial and fungal growth. Becausethese dressings must be frequently changed and the wound exposed topathogens during this changing process, the addition of anti-microbialagents to the wound care dressing helps to reduce the growth of thesepathogens.

[0287] As a result of the above, the use of anti-microbial fibers in themanufacture of wound care dressings provides a practical medicalarticle. These anti-microbial fiber-containing dressings are useful inreducing the growth of bacteria, fungi, and other microbes that can beintroduced from the environment during the changing of dressings andwhile performing other manipulations, thus reducing and preventinginfections generally. Specifically, the anti-microbial-fiber containingfabrics could be used in both the covering fabric and the waterabsorbent interior material. In this way, both surface and interiorprotection could be achieved. In addition, these materials could, ifdesired, be made to be reusable because the anti-microbial effect of thefibers of this invention are resistant to multiple washings. Thus, asignificant cost savings could be realized in the purchasing of suppliesin hospitals and nursing homes as well as in the economics of individualhouseholds.

[0288] In manufacturing these materials, any of the embodiments offibers described above could be used. Both the strength and resiliencyof these materials is important in that they must withstand normalpatient movement and manipulation by health care workers. Thus, bothbi-component fibers and mixed fiber fabrics are useful embodiments forwound care dressings. Also, other modifications of the characteristicsof these fibers and fabrics beyond that of adding anti-microbial agents,including the addition of agents to increase or decrease hydrophobicity,would be useful in manufacturing sturdy dressings. In addition,anti-odor additives may be useful in this application given the exposureof the dressing to various tissue exudates. Thus, these anti-microbialmaterials would then significantly reduce the growth of mold, mildew,and bacteria in wound care dressings.

[0289] Burn dressings may be made with anti-microbial fibers to makevarious materials for a variety of applications in which it is necessaryor desirable to reduce bacterial and fungal growth. Because thesedressings must be frequently changed and the burn exposed to pathogensduring this changing process, the addition of anti-microbial agents tothe burn dressing would help to reduce the growth of these pathogens.

[0290] As a result of the above, the use of anti-microbial fibers in themanufacture of burn dressings is a desirable goal. These anti-microbialfiber-containing dressings are useful in reducing the growth ofbacteria, fungi, and other microbes that can be introduced from theenvironment during the changing of dressings and while performing othermanipulations, thus reducing and preventing infections generally.Specifically, the anti-microbial-fiber containing fabrics can be used inboth the covering fabric and the water absorbent interior material. Inthis way, both surface and interior protection may be achieved. Inaddition, these materials can be made to be reusable because theanti-microbial effect of the fibers of this invention are resistant tomultiple washings. Thus, a significant cost savings could be realized inthe purchasing of supplies in hospitals and nursing homes as well as inthe economics of individual households.

[0291]FIG. 10 shows a wound care or burn dressing 24 which includes abottom layer 18, a top layer 20 and an intermediate absorbent fibrouslayer 22 which joins the other two layers. The bottom layer 18 is useddirectly against the wound or burn and therefore the fibers of thislayer have the anti-microbial agent applied thereto as described below.

[0292] In manufacturing these materials, any of the embodiments of fiberdescribed above can be used. Both the strength and resiliency of thesematerials is important given that they must withstand normal patientmovement and manipulation by health care workers. Thus, bothbi-component fibers and mixed fiber fabrics are useful embodiments ofburn dressings. Also, other modifications of the characteristics ofthese fibers and fabrics beyond that of adding anti-microbial agents,including the addition of agents to increase or decrease hydrophobicity,would be useful in manufacturing sturdy dressings. In addition,anti-odor additives may be useful in this application given the exposureof the dressing to various tissue exudates. Thus, these anti-microbialmaterials would then significantly reduce the growth of mold, mildew,and bacteria in burn dressings.

[0293] Fabric

[0294] Fiber and fabric which are color-fast and which can be for pastelshade fabric, as disclosed, for example, in Serial No. 60/180,536 filedFeb. 7, 2000, the contents of which are physically incorporated hereinbelow, in which PETG which is an amorphous binder fiber is used and isblended into yarns with other fibers to form fabrics, as well as knitsand non-woven fabrics. After heat activation, the PETG fiber melts, wetsthe surface of the surrounding fibers, and settles at the crossingpoints of the fibers, thus forming “a drop of glue” which bonds thefibers together. PETG is also used to carry pigments and/oranti-microbial additives to the fibers, distribute the pigment and/oranti-microbial additives on the surface of the surrounding fibers, andachieve certain colors without the need to dye the fibers and naturalfabrics having anti-microbial qualities. This invention presents amethod for making a pastel shade fabric and/or nature fabrics havinganti-microbial activities by using PETG as a carrier for pigments andanti-microbial additives, blending them with cotton or any other fibers,activating and melting PETG from 110° to 140° C., and leaving theencapsulated pigment and anti-microbial additives on the fibers. Thefinal pastel shade fabric having an excellent fastness for both sunlightresistance and washing without the need of going through a dye bath, andhas the color remain fast for in excess of 100 commercial launderings.If the pastel shade fabric is made by blending PETG and pigments withcotton, after the activation of PETG, the final product can still belabeled as 100% cotton fibers. Thus, the present invention provides afiber, yarn and/or fabric construction. There is a method for making afiber blend which includes mixing a polyester polymer, characterized bya low melting temperature and having binder qualities, with an additivefor providing desired characteristics to a finished fiber. The mixtureis heated and extruded to form a continuous filament. The continuousfilament fiber is cut to form a cut filament fiber. The cut filamentfiber is blended with a natural fiber to form a fiber blend. The fiberblend is heated to a temperature in the melting temperature range ofsaid polyester polymer for a sufficient period of time to melt the lowmelting temperature polyester polymer and wet the natural fiber andprovide such natural fiber with the additive firmly attached thereto.The polyester polymer may be PETG. After the fiber is prepared it may bespun to make a yarn and the yarn may be made into a fabric. The heatingstep can take place after the yarn is made into a fabric. The additivemay be a colorant, an anti-microbial agent, a fire retarding agent, oranother agent which adds properties to the fiber or yarn or fabric.There is another method for making a fiber, which includes mixing apolyester polymer, characterized by a low melting temperature and havingbinder qualities, with an additive for providing desired characteristicsto a finished fiber, heating the mixture and extruding it to form acontinuous filament. Another polymer is heated and extruded to form acontinuous filament. The extruding steps form a bi-component fiber withthe mixture forming the sheath and the other polymer forming the core.The sheath is heated to a temperature in the melting temperature rangeof the polyester polymer for a sufficient period of time to melt the lowmelting temperature polyester polymer and wet the core fiber and providethe core fiber with the additive firmly attached thereto.

[0295] The fabric invention provides a unique way to use polymers suchas PETG to carry and deliver pigments and/or anti-microbial or otheradditives to a natural fiber, such as cotton, wool, and the like, andgenerate a final pastel shade fabric without losing the natural fiber'scharacteristics and/or natural fabric having anti-microbial properties.

[0296] PETG is used as a carrier for pigments, such as carbon black,phthalo blue, and the like. It is mixed with other fibers, such asnatural fibers, to form a blend, and then the blend is heated, to atemperature of around 140° C. (the PETG can be modified to melt between90 and 160° C.) either as a separate heating step or during a processingstep which includes heating to about temperature. PETG has a meltingtemperature of around 140° C. (and is available from 90 to 160° C.) andit melts and flows along the fibers with which it is blended. It acts asa binder-carrier in that it forms nodes of color (when a colorant isused) with many points so it looks like a solid color. This provides itwith a pastel look. By controlling the amount of colorant added to thePETG there is controllable color values which include pastel shading.PETG has superior wetting ability and therefore it spreads evenly alongthe other fibers with which it is blended. There are also nodes formedat the intersecting fibers in the blend and there are held together bythis characteristic of the PETG. Also, the amount of PETG can becontrolled to be small quantities with respect to the other fibers inthe blend. Thus, when blended with cotton in this manner, such a blendmay properly be characterized as “all cotton” having color and/oranti-microbial (or other) agents, which have been added by the PETG.

[0297] This can be accomplished in more than one manner. One method isshown in FIG. 11 in which the PETG and colorant pellets are mixedtogether, after which they are heated to melt and are then extruded toform a PETG fiber with the colorant in it. The PETG is then blended witha natural fiber, such as cotton, to form a blend, which will have thecolor of the colorant, which the PETG fiber takes on as its color. Thecotton is white so that the color taken on is a pastel color. If thecolorant is black, then the blend becomes a shade of gray. If desiredother fibers can be blended with the PETG fibers, such as silk, flax,polypropylene, polyethylene, wool, polyester, acrylic, nylon, PTT, 3GT,rayon, modified rayon, and acetate.

[0298] The PETG is then activated by heating it as a temperature of fromabout 110° to about 140°. This melts the PETG without harming the fiberswith which it has been blended. The PETG carrier melts and wicks alongthe other fibers, that is the cotton or other base fibers, forming smallnodes, but it does not ball up as some polymers do and provides “a dropof glue” (small) to bind the fibers together and leaves behind theencapsulated pigment in the fibers.

[0299] This fiber blend is then used to form a yarn with in turn is usedto form a fabric. The resulting fabric is a pastel shade fabric withoutthe need of going through a dye bath, and has excellent color fastnessfrom both sunlight and washing. The color is a pastel since there aremany tiny drops of the colorant which looks like a solid color to anobserver. The color remains fast for in excess of 100 commerciallaunderings. Since the PETG carrier melted after activation, the blendedfibers such as cotton are still considered to be 100% cotton fiber.

[0300]FIG. 12 shows a method similar to that shown in FIG. 11. However,in this process the blended fiber is made into a yarn and the yarn ismade into a fabric before the PETG is activated by heating. This heatingmay be a separate heating step or may take place during the processingof the fabric which may include a heating step for other reasons.

[0301] The present invention may also be used to provide anti-microbialfibers by using PETG as a carrier for anti-microbial additives. Againthe PETG and the anti-microbial pellets may be melted together to form amelt which is extruded to create a continuous filament which is then cutto appropriate size and is then further blended with natural or otherfibers to provide an anti-microbial finished yarn which may be made intoan anti-microbial fabric that is able to withstand significant wear andwashings and maintain their effectiveness. The anti-microbial additivesare inorganic compounds made from metals such as copper, tin, zinc,silver, and the like. The preferred compound is a zeolite of silverwhich may be dispersed in PE, PET, or PBT before being added to thefiber. The additives can be added directly to the primary polymer withpre-dispersion. The total active ingredients range from 0.1 to 20% byfiber weight. Other inorganic metals such as tin, copper and zinc workalso, but not as well as zeolite of silver.

[0302] The PETG polymers with anti-microbial additives can be blendedwith natural fibers such as cotton, silk, flax, and wool, or syntheticfibers such as polyester, polypropylene, polyethylene, acrylic, nylon,PTT, 3GT, rayon, modified rayon, and acetate to make anti-microbialfinished fabrics that are able to withstand significant wear andwashings and maintain their effectiveness.

[0303] A typical example is a fiber using the PETG polymer with thezeolite contained silver additive blended with cotton up to 10% byweight to produce a bed sheet. The binder fiber is activated during thedrying cycle of the final bleaching operation or other heat operation.The PETG melts and wets the surface of the cotton fibers to carry theanti-microbial characteristics to the entire sheet with an added benefitof increasing strength and reducing pilling.

[0304] The fiber size ranges from 0.7 dTex to 25 dTex and a staplelength of 1.0 mm to 180 mm. A continuous filament yarn can also beproduced that can be used in a wrap spun application whereby fibers arespun around the anti-microbial filament.

[0305] The anti-microbial product withstands more than 50 commercialwashings at 80° C. It is immune to UV exposure of at least 225 kj. Itpossesses excellent abrasion resistance and is unaffected by tests suchas Tabor or Wyzenbeek. It is not affected by at least 50 dry cleanings.

[0306]FIG. 13 is another flow diagram for an arrangement, which providesa bi-component fiber with a PET core and a PETG sheath containing adesired additive, such as pigment and/or an anti-microbial agent. ThePETG and the colorant pellets are placed into a first extruder and PETpellets are placed into a second extruder. Both are heated sufficientlyso that the extruders cause the melts to flow to a single spinneret inwhich the PET is made into the core and the PETG is made into thesheath. In the fiber state, or in a more finished yarn state, or in aneven further finished woven or nonwoven fabric state, the fibers aresubjected to heat in the vicinity of 140° C. which melts the PETGwithout harming the PET which has a higher melting point. This heatingstep provides the benefits of the present invention as discussed above.

[0307] Footwear Components

[0308] Footwear components as disclosed, for example, in pendingprovisional application Serial No. 60/181,251 filed Feb. 9, 2000, thecontents of which are physically incorporated herein below, in which thefootwear components provide several embodiments of anti-microbial and/oranti-fungal footwear products. The footwear components such as insoles,midsoles, box toes, counter and linings of footwear products, e.g.,shoes, slippers, sneakers and the like are provided in which theanti-microbial agent is available for the life of the product and notwashed away or worn away by sweat or abrasion. Also, the anti-microbialagent is placed into the component close to or on the surface which ismost needy of the protection, such as the part of an insole closest tothe foot of a user when the insole, or other component is assembled intoa footwear product. Thus, the fungi or microbes which may form andcreate odors or other problems are killed on contact with the surface ofthe shoe component anti-microbial surface area. The footwear componentscan be a nonwoven fabric of synthetic fibers, primarily polyester, butwhich could be acrylic, nylon, rayon, acetate, PP, and the like. Thefabric can have a weight from 65-400 grams per square meter and typicalfibers range from 1.2 dTex to 7 dTex with a cut length of 25-76 mm. Theyare carded, cross-lapped and needle punched, but could be produced onother types of nonwoven equipment, such as spun laced or spun bondedequipment. The impregnation is a latex of SBR, vinyl acetate, PVC,acrylonitrile, and the like. Impregnation is from 1-4 times the weightof the nonwoven fabric on a dry basis. A range of fillers such as clay,calcium carbonate, and the like are used to reduce the cost. There aretwo basic methods. One is to mix the anti-microbial with latex compoundand impregnate it into the insole. The other is to use anti-microbialfibers on the insole in various manners.

[0309] The footwear components are provided by several embodimentsdescribed herein but may be practiced using other embodiments. There isdescribed below, a first embodiment of a single layer of latex, and asecond embodiment of a main support layer and a fiber layer attachedthereto.

[0310] The foregoing objects are met by footwear components such asinsoles, midsoles, box toes, counter and linings of footwear products,e.g., shoes, slippers and sneakers in which the anti-microbial agent isavailable for the life of the product and not washed away or worn awayby sweat or abrasion. Also, the anti-microbial agent is placed into thecomponent close to or on the surface which is most needy of theprotection, such as the part of an insole closest to the foot of a userwhen the insole, or other component is assembled into a footwearproduct. Thus, the fungi or microbes which may form and create odors orother problems are killed on contact with the surface of the shoecomponent anti-microbial surface area.

[0311] The footwear component can be a nonwoven fabric of syntheticfibers, primarily polyester, but which could be acrylic, nylon, rayon,acetate, PP, and the like. The fabric can have a weight from 65-400grams per square meter and typical fibers range from 1.2 dTex to 17 dTExwith a cut length of 15-180 mm. They are carded, cross-lapped and needlepunched, but could be produced on other types of nonwoven equipment,such as spun laced or spun bonded equipment.

[0312] The impregnation is a latex of SBR, vinyl acetate, PVC,acrylonitrile, and the like. Impregnation is from 1-4 times the weightof the nonwoven fabric on a dry basis. A range of fillers such as clay,calcium carbonate, and the like are used to reduce the cost. There aretwo basic methods. One is to mix the anti-microbial with latex compoundand impregnate it into the insole. The other is to use anti-microbialfibers on the insole in various manners.

[0313] An embodiment of a nonwoven fabric impregnated with latex isshown in FIG. 14 in which there is an insole 54 having a toe portion 56and a mid sole portion 58 and a heel portion 60 all in a single piececonstruction. It is a suitable fabric which is then impregnated withlatex to provide cushioning for wearer comfort. The anti-microbial, inthis case zeolite of silver is mixed with the latex prior toimpregnating the insole.

[0314]FIG. 15 is another arrangement wherein a support and cushioninglayer 62 is provided and which may be any of a number of materials whichare used for insoles, but preferably one which of a nonwoven material. Afiber layer 64 made of fibers which have the anti-microbial agentdisposed therein is attached to cushioning and support layer 62 by anysuitable means. In this arrangement zeolite of silver is theanti-microbial agent. This can include an adhesive, but could also beaccomplished by making the support layer of a polymer which is also usedfor some of the fibers and the fiber layer 64 is attached to the supportlayer 62 as the support layer is first delivered after being preparedand still retains the heat of preparation whereby the common polymer ishot enough to partially melt and then become bonded together.

[0315] Some anti-microbial agents are also anti-fungal agents. Whenagents do not perform both functions, a second agent will usually beused.

[0316] The choice of particle size of the zeolite is based on thethickness of the layer carrying it to obtain the best combination ofsurface area with anchoring in the layer. For example, a very thin layerof 3 m would be best served with a 1-2 m zeolite, which would have amaximum dimension of 2×1.73 or about 3.5 m.

[0317] The inner layer(s) could be made of basically any thermoplasticresin, such as; PE, PP, PET, PS, PCT, Polyamide (nylon), Acrylic, PVC,etc. The surface layer(s) could be made of the same polymers plus somelow temperature ones such as PETG, Polycaprolactone, EVA, etc.

[0318] It is preferable to have the layer closest to a wearer's foothave the anti-microbial and/or anti-fungal agent and be porous toperspiration to absorb perspiration.

[0319] In the event a support layer is used which is not fibrous, it iscovered with a nonwoven fabric, the fibers of which have theanti-microbial agent therein. Such a layer can be thinner than thesupport layer. However, it is usually best if the layers used allowperspiration to be carried away from the wearer's foot for both comfortand health reasons.

[0320] The anti-microbial particles are bonded into the surface layerand remain there for the life of the material and provide anti-microbialproperties for the entire time.

[0321] It is advantageous to have the anti-microbial agent only at thesurface since this is the only area which comes into contact withmicrobes and fungi, and to have the agent located in other places iswasteful.

[0322] Anti-microbial fibers can be used to make the footwear productsof the present invention where it is necessary or desirable to reducebacterial and fungal growth and their resultant odor. In manufacturingthese materials, any of the embodiments of fiber described can be used.Both the strength and resiliency of these materials is important. Anynumber of shaped designs could be used as appropriate.

[0323] Also, other modifications of the characteristics of these fibersand material beyond that of adding anti-microbial agents, including theaddition of agents to increase or decrease hydrophobicity, would beuseful. In addition, anti-odor additives may be particularly useful.

[0324] The relatively small size of the silver-containing zeolitecompounds (2 microns and less) that are used in the manufacturing of thefibers allow these anti-microbial agents to be incorporated into fibersinstead of being applied to them. Thus, because these anti-microbialagents are an integral part of the fiber, they are not washed away byperspiration or easily abraded away and the finished components, such asinsoles, manufactured from them are able to withstand significant wearwhile maintaining their anti-microbial effectiveness.

[0325] Specifically, higher loading of the anti-microbial agents (up to5 times) is used to more effectively act against fungi. This higherloading may be achieved by using various zeolites followed by heatingthe fiber polymer, e.g. PET, to between 180 and 228 degrees Fahrenheitin hot water which allows further metal loading or ion exchange toreplace resident metal ions with another ion or mixture of ions. Inaddition, this would allow the zeolite at or near the surface of thefiber to be preferentially loaded with the metal ion or mixtures thereofthat has the desired biological effect. These methods are particularlyuseful in reducing costs when expensive metal ions, such as silver, areused in these processes. Also, by adding certain metals, e.g. silver, atthis point in the process and not having it present during the hightemperature fiber extrusion process, any yellowing or discoloration dueto oxidation of the metal ion or its exposure to sulfur and halogenswould be greatly reduced.

[0326] It is also possible to use these integrated anti-microbialcompounds to make shoe components and products that have a varyingdistribution of the anti-microbial agent. For example, by varying theconcentrations of the anti-microbial agent during mixture with thefiber-forming polymers, fibers having varying anti-microbial content canbe formed which can then be added in varying amounts to form materialshaving varying concentrations of anti-microbial agents. In addition, theamount of anti-microbial present in the fiber itself can be varied,either lengthwise or in cross-section. Similarly, higher and lowerconcentrations of these anti-microbial agents in the overall fibers canbe achieved by using multi-layered sheets in which, for example, theanti-microbial agent is present only in an outer layer section, thussignificantly reducing manufacturing and selling costs. Any of the abovemanufactured anti-microbial fibers can be mixed with fibers that do notcontain anti-microbial agents such that products can be made havingoverall and localized variations in concentrations of anti-microbialagents.

[0327] In addition, the fibers can be made either hydrophilic orhydrophobic as desired by mixing other agents into the fiber polymers orapplying them to the fiber surface. By modifying the wetabilitycharacteristics of the fibers, they can be made more useful for variousapplications. For example, hydrophilic fibers are effective inapplications in which one wants the anti-microbial material to moreeasily absorb water, such as when the material is designed to be used infootwear. Alternatively, hydrophobic films or fibers are effective inapplications in which one wants to avoid the absorption of suchsolutions. For example, the insole of the present invention could bemade with a hydrophilic agent on the upper surface which will be nearerto the foot of the wearer, while the lower surface which will beadjacent other parts of the footwear, could be made with a hydrophobicto keep the perspiration away from other parts of the footwear.

[0328] Sheet Material

[0329] Sheet material as disclosed, for example in pending provisionalapplication Serial No. 60/180,240 filed Feb. 4, 2000, the contents ofwhich are physically incorporated herein below, in which flat or shapedsheets or films, including wide sheets can be individually extruded orthere can be co-extrusion of flat or shaped films or profiles. Theproduct may be a multi-layer construction with the surface layer, on oneor both sides, containing zeolite of silver (or other metal such as tin,copper, zinc, etc.). The product may be a flat film for use in a flatform for counter tops, floors, walls, or molded into shapes such ascafeteria trays, shoe insoles, serving dishes, high chair table,refrigerator trays, microwave liners, and luggage. As a profile theextrusion may be a rain gutter, a screen enclosure, a counter top, handrailing, duct work, sanitary piping, water pipe, gasket materials arounddishwashers, and the like. The same concept applies to multi-layerinjection molded parts. In this case the surface layer may haveanti-microbial properties in applications such as telephone handsets,baby bottles, computer keyboards, plastic utensils, milk bottles, andthe like. The choice of particle size of the zeolite is based on thethickness of the film to obtain the best combination of surface areawith anchoring in the film. For example, a very thin film of 3μ would bebest served with a 1-2μ zeolite, which would have a maximum dimension of2×1.73 or about 3.5μ. The inner films could be made of basically anythermoplastic resin, such as; PE, PP, PET, PS, PCT, Polyamide (nylon),Acrylic, PVC, etc. The surface layer(s) could be made of the samepolymers plus some low temperature ones such as PETG, Polycaprolactone,EVA, and the like. Anti-microbial films are used to make sheet materialsfor a variety of applications in which it is necessary or desirable toreduce bacterial and fungal growth and their resultant odor. Ananti-microbial sheet material is made of film which comprises variousthermoplastic polymers and additives. The anti-microbial synthetic filmscan comprise inorganic anti-microbial additives, distributed only incertain areas in order to reduce the amount of the anti-microbial agentsbeing used, and therefore the cost of such films. The anti-microbialadditives used in the synthetic film do not wash off over time becausethey are integrally incorporated into these films, thus theireffectiveness is increased and prolonged. The anti-microbial syntheticfilms comprise high tenacity polymers (e.g. PET) in one component andhydrolysis resistance polymers (e.g. PCT) in another component. Thehydrophilic and anti-microbial additives provide a hydrolysis-resistantsurface. If desired, fibers may be included and extruded. For example,such fibers could be used to make the two outer layers of the sheetmaterial using sheath/core arrangements so that the anti-microbial agentis only present in the sheath to reduce the amount of anti-microbialagent which is used.

[0330] The present invention provides several embodiments, some of whichrelate to the co-extrusion of flat or shaped films, sheets or profiles.The product may be a co-extruded multi-layer construction with thesurface layer, on one or both sides, containing an inorganicanti-microbial and/or anti-fungal agent.

[0331] The product may be a flat film for use in a flat form for suchuses as counter tops, floors, walls, or molded into shapes such ascafeteria trays, serving dishes, high chair tables, refrigerator trays,microwave liners and luggage.

[0332] As a profile the extrusion may be a rain gutter, a screenenclosure, a counter top, hand railing, duct work, sanitary piping,water pipe, and gasket materials around dishwashers and garage doors.

[0333] The same concept applies to multi-layer injection molded parts.In this case the surface layer may have anti-microbial properties inapplications such as telephone handsets, baby bottles, computerkeyboards, plastic utensils, milk bottles, automotive interior parts,aircraft/bus/train seat and trim parts, and the like.

[0334] When the anti-microbial is zeolite of silver, the choice ofparticle size of the zeolyte is based on the thickness of the film toobtain the best combination of surface area with anchoring in the film.For example, a very thin film of 3 m would be best served with a 1-2 mzeolite, which would have a maximum cubic dimension of 2×1.73 or about3.5 m. In this manner the anti-microbial particles are at leastpartially exposed and are not completely embedded in the thermoplasticmaterial where they would have no anti-microbial effect unless thecovering surface were abraded away.

[0335] The inner films or layers can be made of basically anythermoplastic resin, such as; PE, PP, PET, PS, PCT, Polyamide (nylon),Acrylic, PVC, etc. The surface layer(s) can be made of the same polymersplus some low temperature ones such as PETG, Polycaprolactone, EVA, etc.

[0336] Sheet Material Laminates

[0337]FIG. 16 shows one type of multi-layer sheet in accordance with thepresent invention. The multi-layer sheet material 66 has a main, thickersupport layer 68 and a surface layer 70 which is a thin layer of athermoplastic material which is sufficiently thin that small particlesof anti-microbial agent are contained therein and have portions thereofwhich are at the surface or just below the surface of the layer. In thisway the anti-microbial particles are bonded into the surface layer 70and therefore remain there for the life of the material or product madefrom the sheet material and provide anti-microbial properties for theentire time. It is advantageous to have the anti-microbial agent only atthe surface since this is the only place where it comes into contactwith microbes and fungi and to have the agent in other places in themulti-layer sheet material is wasteful.

[0338] Another type of multi-layer sheet construction, which may be usedto accomplish the purposes of the present invention is shown in FIG. 17.In this arrangement the multi-layer sheet material 72 has a main supportlayer 74 and both surfaces thereof have surface layers 78 and 80,respectively. One or both of the surface layers 78 and 80 have theanti-microbial agent. Layer 74 is a wide sheet of material which may beextruded of thermoplastic material. It can be a rigid material or aflexible material depending upon the end use. The second and thirdlayers of wide sheet material are attached to it by suitable means knownin the art or they may be co-extruded as described below in connectionwith FIGS. 21-23. There is a surface layer having an anti-microbialagent (which may be or include an anti-fungal agent) is attached to bothsides of the composite layers. These layers are connected by a suitablemeans known in the art when they are not co-extruded.

[0339] This three layer arrangement may be co-extruded at one time sothat the three layers are bonded together immediately after extrusionand while the layers are still hot and prior to quenching. For adiscussion of the co-extrusion process, see FIGS. 21 and 22 and thedescription thereof which appears below.

[0340] There are many uses which may be made of this composite, and theend use is evaluated to determine additional features which are added.For example, if the finished composite of FIG. 16 or FIG. 17 is to beformed into a shape for cafeteria trays or food trays (see FIG. 20),then only one surface layer having the anti-microbial agent is neededand the support layer is rigid to provide rigidity to the tray. Thematerial is hard and smooth so that it may be easily cleaned yet stillprovide the anti-microbial effect. The food tray is die formed after thesheet is made by the co-extrusion process.

[0341] It is possible to form the three layer sheet 72 which includesthe support layer 74 of at least 10 microns in thickness which isextruded at the same time as a second sheet 78 which becomes a two-layersheet, the second sheet being 4 microns in thickness and being supportedby the first layer. The extruding of both layers is done at the sametime and the second sheet 78 is joined to the first sheet 74 before thequenching is complete. If desired a third sheet 80 similar to the secondone, 78, can be made at the same time. The second and third sheets mayhave an anti-microbial agent of the type discussed herein mixed with thethermoplastic material so that the three layer sheet has a thin toplayer and a thin bottom layer which possess anti-microbial properties.

[0342]FIG. 18 shows a multi-layer sheet 82 having a first inner layer 84and a second inner layer 86 with two surface layers 88 and 90. It alsoincludes edge layers 92 and 76, and which is suitable for variouspurposes. It may be constructed as shown in FIGS. 21 and 22 and asdescribed below.

[0343]FIG. 19 shows a multi-layer sheet 94 which has a shape in the formof a curve and which includes a center support layer 96 and two surfacelayers 98 and 100.

[0344]FIG. 20 shows a food tray 102 which may be the type which containsfood and is purchased in food stores with food packaged therein. Thistray includes two basic parts, a bottom 104 and a top 106. The bottom104 may be of PET which is crystallized in order to provide a firm layerwhich may support the food products contained therein. After themulti-layer sheet material is made, the food tray parts are formed indies. This bottom part 104 has a bottom layer 108 and four side-walls110, 112, 114, and 116. For all the parts of the bottom 104, there is aninner layer 118 of a thin film which is attached to a support layer 122and this film 118 contains an anti-microbial agent as indicated by thestippling. There are tabs 124 and 125 on the bottom which fit into holes120 on the top 106. The top is made of a transparent material and is inthe amorphous state. The anti-microbial agent prevents the growing ofmicrobes which are killed upon contact with the inner film layer of thebottom of the food tray.

[0345] Making Co-Extruded Sheet Material Laminates

[0346] With reference to FIGS. 21 and 22, a suitable die has afunnel-shaped expansion chamber 128 terminating in a slotted die outlet128 defined by a pair of spaced die lips. The die has a shallow chamberentrance section 132.

[0347] The feed block 126 comprises a plurality of slotted layerdistribution passages 134 in the form of mutually spaced apart slots oropenings lying substantially parallel to slotted die outlet 128. Thepassages extend from an inlet side to an outlet side of the feed block126.

[0348] The feed block further comprises end encapsulation slots 166 and158 extending between inlet and outlet sides without intersectingpassages 134 and lying substantially perpendicular thereto. Otherwise,slots 166 and 158 may extend along planes converging together from theinlet side to the outlet side. The feed block assembly 152 includes aframe 136 connected to the upstream end of the die in some suitablemanner and defining a chamber (not shown) open on opposite sides tofacilitate removal and replacement of feed block 126 with aninterchangeable feed block designed to accommodate specific resinviscosities, selected polymer matchups, layer thickness changes, layergeometry, etc.

[0349] Frame 136 includes various connectors 138A and 138B to whichextruders (not shown) of polymer melts are connected, and to which feedchannels or feed lines (also not shown) are likewise connected forfeeding the melts to slots 134A-134E, 166 and 158, or to selected onesthereof.

[0350] The feed block may be connected in some suitable manner to frame136 or may be unconnected thereto.

[0351] Apparatus generally designated 152 is illustrated in FIGS. 21 and22 as comprising a slit die 140 of mating die halves. A feed blockassembly, generally designated 150, is totally integrated into the dieas it is inserted within a die cavity 156 open at the upstream end ofthe die and at opposing sides of the die, shown in FIG. 21. Feed blockassembly 150 comprises feed block 126, connectors 138A and 138B and meltfeed lines 141A and 141B, respectively, extending from the connector138A for feeding plastic melt from the extruder to the slotted passages134A, 134B and 134C, and from the connector 138B for feeding plasticmelts from the extruder to the slotted passages 134D and 134E. When ananti-microbial or the like is to be provided in the thinner outer sidesof the sheet material, such an agent is added into the melt which isthen extruded and fed to feed line 141B and connector 138B to extrudingslots 134D and 134E. In the event the edges of the laminated sheetmaterial is to differ from the material fed into feed lines 141A and141B, a third feed line (not shown) can be connected to slotted passages166 and 158 of the feed block. If the edges are not to be different theslotted passages 166 and 158 are not or may be omitted from theconstruction of feed block 126. Thus, the entire feed block assembly 150can be removed from cavity 156 and replaced by another feed blockassembly for a new production cycle.

[0352] Feed block 126 of apparatus 152 can be provided with externallyaccessible means to control the melt streams of polymer melt passingthrough the outermost slots 134D and 134E for adjusting the distributionof the outer or skin layers of the skin laminate to be formed. Suchcontrol means may be in the form of a restrictor bar 154 extendingtransversely to the direction of flow of melt through the passages forcontrolling the width and/or shape of the outermost passage upon manualmanipulation of an adjustment screw 146. The restrictor bar may belocated in a side cavity 148 of the feed block.

[0353] Otherwise, the skin layer control means may be in the form of adriven wedge 164 mating with a drive wedge 160 connected to a screwdrive 142 via flange 162, as more clearly shown in FIG. 22. The wedgesmay be housed in a suitable side cavity 144, and a turning of screwdrive 142 shifts wedge 160 along the screw drive and causes the drivenwedge to be shifted transversely relative to the melt flow through thefeed block for controlling the distribution of the skin layer flowingthrough the outer-most passage of the feed block.

[0354] Restrictor bar 154 can be utilized on both sides of the feedblock, and the wedge arrangement can likewise be utilized on both sides.Restrictor bar 154 and wedge 164 can have flat melt flow engagingsurfaces, or these surfaces can be concavely or convexly shaped orotherwise contoured to control the layer distribution of the skin layersby modifying the outer slots to accommodate differences in meltviscosities, etc.

[0355] With this arrangement one or both outer layers may have ananti-microbial agent. If a three-layer arrangement is made it can have acenter layer of 10 m and the outer layers may be 4 m. In such an eventthe particle size may be about 1.5-2 m. If zeolite of silver particlesare used and made this size then substantially every particle of zeolitewill have at least a portion exposed by projecting through the outersurface of the layer in which it is embedded.

[0356]FIG. 23 shows a die 168 having a single extrusion slot with threeportions, 170, 172 and 174. The sheet which is extruded thereby is shownhaving a center section 176 and two edge portions 178 and 180. The widthof the center portion 176 is the same as the widths of the edge portionstogether. When the extrusion process takes place die slot portion 170produces edge portion 178, die slot portion 172 produces center portion176 and die slot portion 174 produces edge portion 180. The stipplingindicates that an anti-microbial and/or an anti-fungal agent has beenincorporated into the center portion of the extruded sheet. The extrudedsheet is shown having a thickness 182 which is the same throughout,although portions could be of different thickness if this is desired.

[0357] Thus FIG. 23 shows a manner of making a co-extrusion multi-layersheet in which the edges 178 and 180 of the extruded sheet are differentfrom the center 176 in some respect and if desired, after extrusion andwhile still having the heat of the extrusion (prior to quenching) thetwo edge portions 178 and 180 are folded under to provide a layer underthe center section. In this manner a two-layer sheet is formed withlayer 176 having microbe and fungus killing properties on one side ofthe two-layer sheet.

[0358] If desired, the die and sheet could have only two sections ofequal width, in which event one would be folded over the other to formthe two-layer sheet with one layer having anti-microbial properties.

[0359] Construction of the Multi-Layer Sheet Material

[0360] Anti-microbial agents can be used in making sheet materials for avariety of applications in which it is necessary or desirable to reducebacterial and fungal growth and their resultant odor.

[0361] In manufacturing these materials, any of the embodimentsdescribed above could be used. Both the strength and resiliency of thesematerials is important. Any number of shaped designs could be used asappropriate. In some instances, round would be appropriate whereas inother instances rectangular or other shapes, both simple and complicatedwould be appropriate, all depending upon the use to be made of thematerial.

[0362] Also, other modifications of the characteristics of thesematerials beyond that of adding anti-microbial agents, including theaddition of agents to increase or decrease hydrophobicity, is useful. Inaddition, anti-odor additives may be particularly useful in cafeteria orother types of food trays.

[0363] The relatively small size of the preferred anti-microbial agentwhich is silver-containing zeolite compounds (which can be as small as 2microns and less) that are used in the manufacturing of the sheet filmallow these anti-microbial agents to be incorporated into the thin sheetfilms instead of being applied to them. Thus, because theseanti-microbial agents are an integral part of the film, they are notwashed or easily abraded away and the finished articles manufacturedfrom them are able to withstand significant wear and multiple washingswhile maintaining their anti-microbial effectiveness. In the case ofproducts which are thrown away after use, the resistance to washings isnot an important factor.

[0364] Specifically, higher loading of the anti-microbial agents (up to5 times) is used to more effectively act against fungi. This higherloading may be achieved by using various zeolites followed by heatingthe film polymer, e.g. PET, to between 180 and 228 degrees Fahrenheit inhot water which allows further metal loading or ion exchange to replaceresident metal ions with another ion or mixture of ions. In addition,this would allow the zeolite at or near the surface of the film to bepreferentially loaded with the metal ion or mixtures thereof that hasthe desired biological effect. These methods are particularly useful inreducing costs when expensive metal ions, such as silver, are used inthese processes. Also, by adding certain metals, e.g. silver, at thispoint in the process and not having it present during the hightemperature film extrusion process, any yellowing or discoloration dueto oxidation of the metal ion or its exposure to sulfur and halogenswould be greatly reduced.

[0365] The synthetic films used in the present invention can be made ofvarious polymers and co-polymers, including thermoplastic ones. Thesepolymers include, but are not limited to, polyethylene (PE),polypropylene (PP), poly 1,4 cyclohexylene dimethylene terephthalate(PCT), PET, PET type G (PETG), co-PET, and co-polymers generally. Thesefilms can also contain styrene, Halar®, and various polyamides.

[0366] As defined in this invention, anti-microbial means athousand-fold reduction in bacteria. Thus, the materials and products ofthis invention are subjected to tests which show a 1000-fold reductionin colony forming units (CFU) of bacteria. To kill bacteria means a tenthousand-fold reduction in bacteria and the materials and products ofthis invention are capable of a 10,000-fold reduction in CFU ofbacteria.

[0367] This level of antibacterial protection is achieved generally byhaving between 0.1 and 20 percent by weight of an anti-microbial agentincorporated into a multi-layered sheet material. Alternatively, theanti-microbial agent concentration can be reduced to between 0.2 and 6.0percent in multi-layer sheets in which the anti-microbial agent is onlymixed into the outer layer(s) of the multi-layer sheet. This latterconfiguration allows less anti-microbial compound to be used, thussignificantly reducing the cost of manufacture, and thus the cost of thesheet material.

[0368] It is also possible to use these integrated anti-microbialcompounds to make sheet materials and products that have a varyingdistribution of the anti-microbial agent. For example, by varying theconcentrations of the anti-microbial agent during mixture with thefilm-forming polymers, films having varying anti-microbial content canbe formed which can then be added in varying amounts to form sheetmaterials having varying concentrations of anti-microbial agents. Inaddition, the amount of anti-microbial present in the film itself can bevaried, either lengthwise or in cross-section. Similarly, higher andlower concentrations of these anti-microbial agents in the overall filmscan be achieved by using multi-layered sheets in which, for example, theanti-microbial agent is present only in an outer layer section, thussignificantly reducing manufacturing and selling costs. Any of the abovemanufactured anti-microbial films can be used with films that do notcontain anti-microbial agents such that sheets and products can be madehaving overall and localized variations in concentrations ofanti-microbial agents.

[0369] Color pigments can be added to these anti-microbial films inorder to provide a pleasing coloration for such sheet materials when theultimate products are purchased by consumers. Similarly to the aboveanti-microbial agents, these pigment materials can be added such thatthe pigments are encapsulated in the polymers that are used to makethese sheet materials. By using this method of coloring the films,materials for end use products made from these colored films arecolor-fast and do not leach out their color during washing, thussignificantly reducing fading during use and washing. In addition, sincethe need for conventional dyeing techniques can be reduced oreliminated, the disposal of environmentally damaging dye materials isavoided. This, in and of itself, can reduce the costs of manufacturingfinished colored sheet materials due to the elimination of themanufacturing infrastructure and associated personnel needed to processresidual dye effluents.

[0370] In a similar fashion to anti-microbial agents and color pigments,a variety of other additives that are used for various purposes can becombined with the polymers during or after film formation and extrusion.For example, additives that protect against damage from UV light can beadded to the film polymer or coated onto it so that the sheet materialsor end use products formed are resistant to the fading of colors and UVdamage generally, although this is not a factor for all products. Bothflame-resistant and -retardant agents can also be added to the films ofthis invention in a manner similar to that described for UV protectingagents. In this way, the sheet materials formed can be made resistant tofire.

[0371] In addition, the films can be made either hydrophilic orhydrophobic as desired by mixing other agents into the film polymers orapplying them to the film surface. By modifying the wetabilitycharacteristics of the films, they can be made more useful for variousapplications. For example, hydrophilic films are effective inapplications in which one wants the anti-microbial sheet material tomore easily absorb water, such as when the material is designed to beused in humid conditions. Alternatively, hydrophobic films are effectivein applications in which one wants to avoid the absorption of suchsolutions.

[0372] The anti-microbial agents can also be added to low-melt polymerfilms that can be activated and melted during sheet material productionby raising the temperature, thus spreading the anti-microbial agentsthroughout the material when the low-melt films melt and coat thesurface of the supporting layer. By varying the amount ofanti-microbial-containing low-melt film regionally and/or by varying theamount of anti-microbial agent in these low-melt films, a sheet materialcan be produced that has a purposely designed regional variation inanti-microbial effectiveness throughout.

[0373] Specifically, the latter situation can be achieved by using anamorphous binding film such as PETG, which can be blended to formvarious types of sheet materials. After heat activation, the PETG melts,wetting the surface of the surrounding films adjacent surface orsurfaces. In this way, solidified PETG forms and binds the layerstogether while spreading the anti-microbial agent throughout thesurfaces. Because of the excellent wetting characteristics of PETG, theanti-microbial agent can be uniformly distributed throughout thematerial. These methods of activating PETG may also be used toadditionally distribute other additives described above throughout thefinished materials.

[0374] The anti-microbial additives used are metals such as copper,zinc, tin, and silver as part of an inorganic matrix. The best resultscan be obtained using a zeolite of silver dispersed in a PE, PP, PS,Nylon, PET, or PBT carrier. These additives can be added directly to themelt without a carrier. The total anti-microbial additive concentrationranges from 0.2 to 6.0 percent by weight of fiber depending onperformance requirements. Other additives which can be incorporatedinclude one or more of UV stabilizers at 0.1 to 5.0 percent;fire-retardant additives at 0.1 to 5.0 percent; pigments at 0.1 to 5.0percent; hydrophilic additives at 0.2 to 5.0 percent; and hydrophobicadditives at 0.2 to 5.0 percent.

[0375] Another configuration of the present invention is a multi-layeredfilm in which the components are the same polymers and additives asdescribed above. In this embodiment one layer is used for strengthanother layer is used as a binder that contains inserted additives.Variants of this such as three and four layered products, and even up toten layered products with the outer two layers carrying theanti-microbial agent can also be made.

[0376] It should be understood that the nominal binder or bindercomponent can also be a strength enhancer in some combinations. It willalso be understood that other variants including but not limited tocombinations, can be made. For example, a first extrusion could produceintermediate film products and such products could be put together witheach other or with separate layers.

[0377] Another embodiment is a grouping of layers used to practice theinvention. One configuration uses PET or other high tenacity polymer atbetween 20 and 80 percent by weight. Poly 1,4 cyclohexylene dimethyleneterephthalate (PCT) or other hydrolysis resistant polymer is used inanother layer at a ratio of 80 to 20 percent. One layer is designed toprovide the strength and the modulus can be varied to create a highmodulus layer, or a low modulus layer, or anywhere in between. The useof PCT in the a layer provides a hydrolysis resistant surface andresistance to long term washings in boiling water and strong soaps. Themulti-layer anti-microbial/anti-fungal synthetic layers can be producedin a wide range of thicknesses.

[0378] Additives include pigments, compounds to create a hydrophilicsurface, and anti-microbial, anti-fungal, and anti-odor agents. Thepigment additives provide uniform colors that do not fade significantlyover long-term use and washing, unlike dyes, because these additives areintegrally mixed within the polymer making up the sheet or film. Inaddition, compounds may be used which create a hydrophilic surface. Theanti-microbial, anti-fungal and anti-odor additives can be varied, bothin types and amounts, depending on the final product desired.

[0379] One layer made from low temperature polymers with a melting orsoftening temperature below 200 degrees C., such as PETG, PE, PP,co-PET, or amorphous PET, may be used as binder carrier foranti-microbial additives.

[0380] The anti-microbial additives are inorganic compounds of metalssuch as copper, tin, zinc, silver, etc. The preferred compound is azeolite of silver dispersed in PE, PET, or PBT before being added to thelayer. The additives could be added directly to the primary polymer withpre-dispersion. The total active ingredients range from 0.1 to 20percent by sheet weight.

[0381] Thus, an anti-microbial sheet material can be produced that isable to withstand significant wear and washings and maintain itseffectiveness.

[0382] Office Partition and Office Component Fabrics

[0383] Office partition and office component fabrics, an example beingshown in FIG. 27 which is a cross section through an office partition inwhich there is a multi-layer partition having a filling layer 240, afabric layer 242 on one side and a third layer 244 which may also be offabric or can be of a solid material. Office type partitions walls canbe portable or semi-portable divers of open area for personnel workstations and other assigned work and waiting areas for employees andclients. The fiber can be wholly or partly synthetic fibers which ismono-or multi-component and can be used with other synthetic or naturalfibers to form a variety of fabrics uses as wall covering and/or wallfillers. Partitions of this type are used in office factory, storage andcustomer service areas. They are provided with fabric surfaces (woven,knits, or non-woven) for aesthetic reasons, sound absorption and/or tocushion impacts. They may also be divided with internal fabric or loosefiber fills for cushioning, wall covering substrate support and soundand/or thermal insulation purposes. The anti-microbial agent isincorporated into the fibers in one or both of the outer layers 240 and244. This can include fabrics for office, hospital, waiting area,classrooms, busses, cars, and the like and also curtains, upholstery,carpets and bedspreads. In addition to the anti-microbial agent, othermaterials can be added to the fibers such as pigments, fire retardants,color fixing agents, and UV resistant agents. Partitions are assembled,disassembled, moved and reassembled with some frequency. This andtraffic around such partitions creates an environment for spread ofairborne or contact transmitted disease, and partitions are frequentlytouched. This invention provides partition systems and other articles ofthe type described. An anti-static agent can be added to assist indissipating static charges which create problems, for example, whencomputers are being used. The product remains intact when subjected tonormal cleaning and can be assembled by being needle punched, resinbonded wet laid, thermo-bonded, and spun bond. In office environmentsthere is the spillage of food and spills from office supply andjanitorial materials and simple hand contact on wall surfaces. These andother environmental insults have the potential to leave residues thatcan be good substrates for the growth of bacteria, mold and othermicrobes. They can be in moist environments and the partitions are sitefor growth, and also from airborne microbes.

[0384] Car Wash Materials

[0385] Car wash materials, including shami type materials, in which theanti-microbial features last for the normal life of car wash cloths, forexample, from 6 to 9 months. In car washes, many types of fabrics areused in the washing process. For instance, the automatic machines thatwash cars use a variety of shaped fabrics to clean the car. In addition,cloths of various kinds are used in the waxing, dying, and finishingprocesses. Due to their continual contact with water, which itself isoften recycled, these materials are often wet for long periods of time.This type of situation is very favorable to the growth of bacteria,fungi, and other microbes. As a result of the above, the use ofanti-microbial fibers in the manufacture of materials used to clean carsin car washes is a desirable goal. These anti-microbial fiber-containingmaterials are useful in materials used by the automatic machinery and byindividuals employed to clean the cars as well as in other ancillarymaterials. Specifically, the shaped fabrics used for automaticallycleaning the car and the hand towels used to wax, dry, and otherwisefinish the car are better products when these anti-microbial fibers areadded to them. In manufacturing these materials, any of the embodimentsdescribed above could be used. Both the strength and resiliency of thesematerials is important given that they are used multiple times and aresubject to being constantly in contact with water. Thus, bothbi-component fibers and mixed fiber fabrics are useful embodiments forcar wash materials. Also, other modifications of the characteristics ofthese fibers and fabrics beyond that of adding anti-microbial agents,including the addition of agents to change the hydrophobicity, areuseful in view of their constant contact with water. Thus, theseanti-microbial materials that are manufactured to be used in car washessignificantly reduce the growth of mold, mildew, and bacteria. Byachieving this goal, odors associated with the long-term use of thesematerials is reduced. Also, the number of times they can be re-usedbefore being discarded is increased, both because of the incorporationof anti-microbial fibers into these materials and the strengtheningstrategies indicated above. These characteristics also result in asignificant costs savings in the operation of car washes. Thehydrophilic and anti-microbial additives provide a hydrolysis-resistantsurface that results in long-term protection against washings in boilingwater and strong soaps, and also degreasers and chemical based cleaners.The anti-microbial synthetic fibers can further be blended withnon-anti-microbial fibers such as cotton, wool, polyester,polypropylene, acrylic, nylon and the like, to provide anti-microbialfinished fabrics that are able to withstand significant wear andwashings and while maintaining their effectiveness;

[0386] Car Wash Water Filters

[0387] Car wash water filters are more useful when the anti-microbialfibers are used in the making of such filters. Also batts and “brillo”type pads can be used which float, or are submerged in a recycled waterstorage tank, and the anti-microbial fibers included in them kill themicrobes, which are in the tank. This is especially important in carwashes, which recycle the wash water, which is the majority of carwashes. In car washes, the water that is used to wash the cars and theassociated materials for performing the washing and drying operations isoften recycled water. However, there are several disadvantages to usingrecycled water. These include the dirt and odor-causing materials foundin the water, including various bacteria, fungi, and other microbes.Because of the use of recycled water, very favorable conditions existfor the growth of bacteria, fungi, and other microbes. As a result ofthe above, the use of anti-microbial fibers in the manufacture of filtermaterials used to clean the recycled water before re-use in car washesis a desirable goal. These anti-microbial fiber-containing filters areuseful in reducing the build-up of biological materials and films, bothon the machinery employed to clean fabrics and other materialsassociated with the car wash process, due to the recycled water re-use.Specifically, the shaped fabrics used for automatically cleaning the carand the hand towels used to wax, dry, and otherwise finish the car areless prone to the development of bacterial and fungal films. They arealso less likely to impart undesirable odors to the car itself. Inaddition, the recycled water itself would be less likely to impart anyodors to the car. They assist in improving the air quality for customersas they drive through a car wash, and also for the employees. Inmanufacturing these materials, any of the embodiments described abovecould be used. Both the strength and resiliency of these materials isimportant given that they are used multiple times and are subject to thehigh pressures characteristic of filtering processes. Any number offilter shape designs could be used as appropriate to the step in thefiltration that was being performed. In some instances, round filterswould be appropriate whereas in other instances pleated or other shapefilters would be appropriate, all depending on the pressure and volumecharacteristics of the recycled water flow. Also, the batts mentionedabove can be used in the recycled water storage tanks or sumps to assistin cleaning the water by killing microbes and fungi. Anti-odor additivesmay be particularly useful in this application given the use of recycledwater. Thus, these anti-microbial car wash filters and battssignificantly reduce the growth of mold, mildew, and bacteria in therecycled water and on car wash materials. By achieving this goal, odorsassociated with the long-term use of recycled water and these materialswould be reduced. Also, the number of times the recycled water and thecar wash materials could be re-used before being discarded could beincreased. The ability to re-use recycled water several additional timesbecause these types of filters and/or batts are employed in the recycleprocess would results in a significant costs savings in the operation ofcar washes.

[0388] Institutional Products and Home Furnishings

[0389] Institutional products and home furnishings, such as bed sheets,pillow cases, mattress pads, blankets, towels, drapes, bedspreads,pillow shams, carpets, walk-off mats, napkins, linens, wall coverings,upholstered furniture, liners, mattress ticking, mattress filling,pillow filling, carpet pads, upholstery fabric and the like, aresignificantly improved when made using, at least in part, theanti-microbial fibers described above. Further details of theseinstitutional products and home furnishings are provided below.

[0390] Mattress pads ½″ to 1″ in thickness are made, for example, as setforth in Example 1 above. The web can be air laid and the binder fibermelts in an oven. Thus, the sheath is melted and spreads on the otherfibers. 5% of the fiber blend mass can be anti-microbial fiber. Theentire sheath is anti-microbial fiber.

[0391] Bed sheets and pillowcases can be made of anti-microbial fiber.They can be constructed using low melt binder fiber blended in at levelsof 1 to 20%. The binder fiber can be blended with other fibers such ascotton, wool, polyamides, viscose, flax, acrylic, or polyester. The lowmelt binder fiber contains levels of the active anti-microbialingredient ranging from 0.25% to 5%. Fiber properties are from 0.7denier through 25 denier with cut lengths ranging from 1 mm to 180 mm.

[0392] The bed sheets and/or pillowcases can also be constructed usingthe bi-component sheath/core polyester fibers with the activeanti-microbial ingredient in the sheath only.

[0393] The anti-microbial fibers are used to spin yarn in cotton countsranging from 4's to 80's. Sheets and pillowcases may be woven orknitted. Yarns used to weave the bed sheets/pillowcases, containing theanti-microbial treated fibers, may be used only in the warp direction,or the filling direction, or may be used in both.

[0394] Some sheets and pillowcases have been made using 1-15%anti-microbial fiber in the fabric, which are 1.5-3.5 denier, 1½″ staplelength and in which 15% of the filling yarn is anti-microbial. Forexample, they can have 15% anti-microbial fiber, 35% cotton and 50%untreated polyester.

[0395] PETG is blended with the cotton, and is heated, it does not ballup but wicks along the other fibers. The cross section becomes thinneras the PETG flows. For loose knit fabrics 15-20% anti-microbial fiber isuseful to kill the microbes, whereas for flat woven fabric there can be10% or less anti-microbial fiber to kill microbes.

[0396] The same fabric can be used in bed sheets and for medical scrubs.Woven fabric is desized to remove starch from the warp yarns. High loftbatting is used to stuff the mattress pad. 15% of fiber blend isbi-component. In one example, the fiber was made with all PET sheath andcore, and was 6½ oz per square yard, 6 denier blended with 6 denierregular while.

[0397] Anti-Microbial Products for Institutional and Home Furnishings

[0398] Institutional and home furnishings include a variety of itemssuch as bed sheets, pillow cases, mattress pads, blankets, towels,drapes, bedspreads, pillow shams, carpets, walk-off mats, napkins,linens, wall coverings, upholstered furniture, liners, mattress ticking,mattress filling, pillow filling, carpet pads, upholstery fabric, andeach of these have different requirements depending upon their intendeduse. While topical applications of agents have been used in the pastthey do not stand up to wear and to repeated launderings. Therefore, thepresent invention provides for the addition of such agents, such asanti-microbial agents at the fiber making stage of manufacture and priorto the fabric or material or product being prepared.

[0399] Bed Sheets and Pillow Cases

[0400] These will usually have the same requirements and be prepared ina similar manner. Fibers and yarns have been prepared to haveanti-microbial properties and then are used to make bed sheets andpillow case material which is then made into the final product.

[0401] Mattress Pads

[0402] The anti-microbial fibers are used for the top and bottom layersof the pads which are sealed or connected to each other along theirperimeters. This can be by sewing with thread or in some other suitablemanner. The center is filled with a batting material which includes 15%anti-microbial fiber produced as described below. The top and bottomlayers are woven fabric which is made from yarn which contains 15%anti-microbial fiber produced as described below.

[0403] It has been found that when these fabrics are dyed, the dyeingprocess can have the effect of blocking the anti-microbial action.However, in accordance with the present invention this problem isresolved by using hot water soaks or washes which rejuvenates thefiber's anti-microbial agents.

[0404] Anti-microbial fibers can be used to make materials for a varietyof applications in which it is necessary or desirable to reducebacterial and fungal growth and their resultant odor. Specifically, ininstitutional environments, these materials can be used in supportsubstrates for furnishings. In these situations, these support materialsare subject to a variety of environmental insults that can cause thegrowth of bacteria, fungi, and other microbes. These include thespillage of food and its seepage inside furnishings and spills fromjanitorial materials. These and other environmental insults have thepotential to leave residues that can be good substrates for the growthof bacteria, mold, and other microbes. Therefore, unsanitary conditionscan occur along with the associated bad odor, both of which cancontribute to patient sickness and allergy, a deterioration of patientmorale, and sick building syndrome, in general.

[0405] As a result of the above, the use of anti-microbial fibers in themanufacture of support substrates for institutional furnishings is adesirable goal. These anti-microbial fiber-containing support substratesare useful in reducing the build-up of biological materials and films,thus reducing associated patient discomfort and environmentalcontamination. Specifically, the anti-microbial-fiber containing supportsubstrates could be coated with polyvinyl chloride (PVC) or laminated towoven or knit fabrics in the construction of institutional furnishings.

[0406] In manufacturing the furnishing type materials, both the strengthand resiliency of these materials is important given that they muststand up to a variety of environmental insults, frequent moves, andvarying storage conditions. They must also be strong enough to act assupporting members of the furnishings themselves. Thus, bothbi-component fibers and mixed fiber fabrics are useful embodiments forsupport substrates for institutional furnishings. Also, othermodifications of the characteristics of these fibers, their associatedfabrics, and support materials beyond that of adding anti-microbialagents, including the addition of agents to increase or decreasehydrophobicity, are useful given the need for frequent cleanings andwashings. In addition, anti-odor additives may be particularly useful inthis application given this frequency of cleaning as well as the varietyand number of environmental insults to which these fabrics are exposed.

[0407] Thus, these anti-microbial materials that are manufactured to beused in support substrates for institutional furnishings significantlyreduce the growth of mold, mildew, and bacteria in the institutions. Byachieving this goal, odors associated with the long-term use of thesematerials and their frequent storage and re-use is reduced. Also, thelength of time that these furnishings can be used in the officeincreases greatly, thus resulting in a significant costs savings in thefurnishing of institutions.

[0408] Color pigments may be added to these anti-microbial fibers inorder to provide the desired coloration for finished fabrics andmaterials. Similarly to the above anti-microbials, these pigmentmaterials can be added such that the pigments are encapsulated in thepolymers that are used to make these fabrics. By using this method ofcoloring the fibers, materials and fabrics made from these coloredfibers are color-fast and do not leach out their color during washing,thus significantly reducing fading during wear and washing. In addition,since the need for conventional dyeing techniques can be reduced oreliminated, the disposal of environmentally damaging dye materials isavoided. This, in and of itself, can reduce the costs of manufacturingfinished colored fabrics due to the elimination of the manufacturinginfrastructure and associated personnel needed to process residual dyeeffluents.

[0409] In a similar fashion to anti-microbial agents and color pigments,a variety of other additives that are used for various purposes can becombined with the polymers during or after fiber formation andextrusion. For example, additives that protect against damage from UVlight may be added to the fiber polymer or coated onto it so that thefabrics and materials formed are resistant to the fading of colors andUV damage generally. Both flame-resistant and -retardant agents can alsobe added to the fibers of this invention in a manner similar to thatdescribed for UV protecting agents. In this way, the fabrics andmaterials formed can be made resistant to fire. Anti-stain agents canalso be added to the fibers or resultant fabrics in the above manner.

[0410] In addition, the fibers can be made either hydrophilic orhydrophobic as desired by mixing other agents into the fiber polymers orapplying them to the fiber surface. By modifying the wetabilitycharacteristics of the fibers, they can be made more useful for variousapplications. For example, hydrophilic fibers are effective inapplications in which one wants the anti-microbial fabric or material tomore easily absorb water, such as when the fabric is designed to absorbsolutions containing bacteria and fungi and other microbes.Alternatively, hydrophobic fibers are effective in applications in whichone wants to avoid the absorption of such solutions, such as in themanufacture of clothing, in general, and in work clothes, in particular.

[0411] The anti-microbial agents can also be added to low-melt polymerfibers that can be activated and melted during fabric production byraising the temperature, thus spreading the anti-microbial agentsthroughout the fabric when the low-melt fibers melt and coat theinterstitial intersections of the other fibers. By varying the amount ofanti-microbial-containing low-melt fiber regionally and/or by varyingthe amount of anti-microbial agent in these low-melt fibers, a fabric ormaterial can be produced that has a purposely designed regionalvariation in anti-microbial effectiveness throughout.

[0412] Specifically, the latter situation can be achieved by using anamorphous binding fiber such as PETG, which can be blended into yarnsand with other fibers to form fabrics and materials. After heatactivation, the PETG fibers melt, wetting the surface of the surroundingfibers and settling at the junctions of other heat-stable fibers. Inthis way, solidified drops of PETG form at these junctions and bind thefibers together while spreading the anti-microbial agent throughout thefiber. Because of the excellent wetting characteristics of PETG, theanti-microbial agent can be uniformly distributed throughout the fabric.These methods of activating PETG fibers may also be used to additionallydistribute pigments and the other additives described above throughoutthe finished fabrics and materials.

[0413] The binder fiber carrier containing polymers and anti-microbialadditives can be blended with non anti-microbial fibers such as cotton,wool, polyester, acrylic, nylon, PTT, 3GT, rayon, modified rayon, andacetate to form anti-microbial finished fabrics. Thus, an anti-microbialfinished fabric is produced that is able to withstand significant wearand washings and maintain its effectiveness.

[0414] A typical example of this embodiment is a fiber using PETGpolymer with a silver zeolite additive to blend with cotton atconcentrations up to 10 percent by weight to produce a bed sheet. Thebinder fiber is activated in the drying cycle of the final bleachingoperation or other heat operation. The PETG then melts and wets thesurface of the cotton fibers to carry the anti-microbial property to theentire sheet with an added benefit of increasing strength and reducingpilling.

[0415] Athletic Wear

[0416] Athletic wear clothing and liners, including athletic wear linersmade from a wholly or partly synthetic fiber that can be wither mono-ormulti-component in nature, and binder fibers both staple and filament,with anti-microbial properties and which can be used with othersynthetic or natural fibers to form a variety of fabrics and materials.Athletic wear is subject to the accumulation of bacteria, fungi, andassociated odors that can proliferate in the presence of sweat and otherbodily secretions that result from strenuous exercise in this type ofclothing. This type of product may be made using anti-microbial fibers,and which for some applications are provided with a layer which touchesthe skin and wicks away the sweat to make a more comfortable garment (orliner) and this type of article benefits from the use of anti-microbialfibers in at least one layer. They can include T-shirts, crotch liners,bicycle pants and shirts, sweat suits, athletic supporters, stretchpants, long underwear, and athletic socks. Because this type of clothingis constantly and intermittently being soaked with sweat and broughtinto contact with dirt and associated materials, they are subject tobacterial and fungal growth as well as to the development of associatedodors. By manufacturing this clothing with lining materials made, atleast partially, of the anti-microbial fibers of this invention, growthof microbes could be reduced. In addition, the exacerbation of microbialgrowth and resultant odor production upon storage of this type ofclothing in bags over time could be reduced. These anti-microbialfiber-containing clothing is useful in reducing the growth of bacteria,fungi, and other microbes once soaked with sweat, thus reducingassociated odors and the discomfort of the individual. Specifically, theanti-microbial-fiber containing fabrics may be used in the interiorlinings of shirts and pants or shorts, such as those used in running andbicycling. These anti-microbial fibers may also be used in themanufacture of athletic clothing that does not have linings. This typeof athletic clothing is then able to be used for long periods of timewhile maintaining its anti-microbial and anti-odor properties because ofits resistance to multiple washings. In addition, the methods describedabove could also be used to produce clothing dyed in a variety of colorsthat would possesses the characteristics of inhibiting microbial growthand its associated odors, thus increasing its versatility.

[0417] Mop Head Fabrics

[0418] Mop head fabrics can be of fibers in yarns, knitted fabrics,woven fabrics or non-woven fabrics. Mop head fabrics are subject tobacterial and fungal growth due to their constantly being wetted uponuse, and are left wet in storage and allowed to air-dry. This constantwetting also causes the development of odors and the eventualdeterioration of the integrity of the mop head materials themselves. Mopheads can transfer bacteria and fungi from one area to another and thuscan be the cause of significant collections of microbes and fungi. Thus,these mop head fabrics made from anti-microbial materials significantlyreduce the growth of mold, mildew, and bacteria. By achieving this goal,odors associated with the long-term use of these materials are reduced.Also, the number of times they may be re-used before being discarded isincreased, both because of the incorporation of anti-microbial fibersinto these materials and the strengthening strategies indicated above.These characteristics also result in a significant costs savings in theuse of mop heads in industrial settings.

[0419] Medical Wipes

[0420] Medical wipes are made using anti-microbial fibers in theirmanufacture. These anti-microbial fiber-containing medical wipes areuseful in reducing the growth of bacteria, fungi, and other microbesthat can be introduced from the environment during the cleaning ofsurfaces in institutional settings, thus reducing and preventinginfections generally. Specifically, the anti-microbial-fiber containingfabrics may be used in both the covering fabric and the water absorbentinterior material. In this way, both surface and interior protection canbe achieved. In addition, these materials could also be manufactured asreusable wipes because the anti-microbial effect of the fibers of thisinvention are resistant to multiple washings. Thus, a significant costsavings could be realized in the purchasing of supplies in a variety ofinstitutional settings, including hospitals and nursing homes.

[0421] The finished product may be constructed of nonwoven, knit, wovenor other process. It may also be treated or pre-moistened with a topicaltreatment such as a soap solution or other additive. The finishedproduct can be produced from any combination of natural or syntheticfiber in addition to the anti-microbial fibers. The wipe cloth may beunitary or combined or laminated to some other fabric.

[0422] In manufacturing these materials, any of the embodimentsdescribed above or below can be used. Both the strength and resiliencyof these materials is important given that they must withstand thecleaning of multiple surfaces. Thus, both bi-component fibers and mixedfiber fabrics are useful embodiments for medical wipes. Also, othermodifications of the characteristics of these fibers and fabrics beyondthat of adding anti-microbial agents, including the addition of agentsto increase or decrease hydrophobicity, are useful in manufacturingsturdy medical wipes. Also, anti-odor additives are useful in thisapplication given the exposure of the wipes to a variety of biologicaland chemical environmental contaminants. Thus, these anti-microbialmaterials can significantly reduce the growth of mold, mildew, andbacteria in medical wipes.

[0423] In one multi-layer embodiment, there is a skin contacting layerwhich contains the anti-microbial fibers, an absorbent layer adjacent tothe first layer and which contains a cleaning solution, a non-permeablelayer adjacent the absorbent layer to prevent the user being contactedwith the solution or by any of the products from a wound, and a tabattached to the non-permeable layer as a handle for the user.

[0424] Dust Masks

[0425] Dust masks are vulnerable to the capture and seeding of bacteriaand fungi. They can provide hospitable sites for the protected growthand the inhalation/exhalation of microbes. These products benefit fromhaving anti-bacterial and anti-fungal agents incorporated into them.Dust masks may be of a nonwoven construction of anti-microbial fibers(at least in part) and may be covered on one or both sides with a fabriclayer. Such masks which can have or provided anti-microbial containingfilters are useful in reducing the build-up of biological materials onthe dust mask which could be inhaled by the user. Both bi-componentfibers and mixed fiber fabrics are useful embodiments for dust masks.Other agents may be used as disclosed herein. [Fos P51]

[0426] Fibrous Media

[0427] Humidifier evaporation surface media introduces an anti-microbialfiber into the evaporation surface media for humidifiers. Such a mediaprevents the growth of mold, mildew, bacteria, and fungi on the media.Preventing such growth reduces or eliminates the “musty smell” currentlyexperienced when such devices are started up to humidify home or officeenvironments. It reduces or prevents the growth of organisms inhumidifier systems to prevent odor and bacterial growth. The media maybe made of a nonwoven fibrous material made at least in part of theanti-microbial fibers disclosed herein. FIG. 28 is a schematic view of ahumidifier evaporation surface media, which is made at least in part ofanti-microbial fibers, used to humidify air. FIG. 29 shows a humidifierpad which could float on the surface of a tank, be attached to thebottom or sides of the tank, or in the suction or discharge sides of thecirculation pump, and it is made at least in part of the anti-microbialfiber disclosed herein. FIG. 28 shows a “fish tank” circulation/aerationsystem. An anti-microbial pad or filter is on the suction or dischargeside of the pump or attached to the bottom on the sides of the tank.This helps prevent the growth of microbes in recirculation systems andtanks which can not use chemicals or in which it is desired not to usechemicals. This and other uses for anti-microbial fibers in differentenvironments show that a person working, for example, in a moldy ordirty environment would want as much assistance as possible in arespirator or filter or mask. Also, one wants the anti-microbial agentto remain in the fiber and not be inhaled by the user.

[0428] Boat Bilge Pads

[0429] Boat bilge anti-microbial pads can be made at least in part withanti-microbial fibers can be used in a filter in the system or can beused in a manner similar to that of the car wash filter in pads whichare placed into the water storage tank to kill bacteria in the water.

[0430] Laundry Bags

[0431] Laundry bags can be made at least in part of anti-microbialfibers as described herein to reduce odors and to kill bacteria whichmay be present in the bags.

[0432] Apparel

[0433] Apparel can be made using anti-microbial fiber as describedelsewhere herein.

[0434] Insoles

[0435] A further embodiment of practice of the invention is shown inFIGS. 24 and 25 wherein an insertable innersole 210 for shoes and bootsis made up of multi-layers indicated in FIG. 24. The layering isindicated before heating and pressing this laminate to form a bondedconstruction. The innersole has anti-microbial that are available in theas fully manufactured product and, as in other embodiments of theinvention described above, are provided in a cost efficient way.

[0436] A top layer 212 of the laminate is made of a non-woven or wovenarray of fibers, preferably of polyester, has an overall weight of 2.5to 6.0 oz. per square yard and includes some 5-25% of its weight asfibers that are mono-component or multi-component and incorporatezeolites of silver or other anti-microbial dispersed substantiallyuniformly in the layer. In eventual processing the surface 213 getstreated by embossing, ultrasonic bonding and/or other modification andthe layer as a whole is heated (along with heating and pressing thelaminate as a whole) to effect, among other things, bonding of fibers atmany cross over points (nodes) 212N in a manner well known in the art toeffect densification and strength while retaining substantial porosityand moisture vapor permeability through the layer.

[0437] The next major layer 214 is made of thermo-formable polymers,preferably polyesters and/or co-polyesters including 20-80 weightpercent of mono-component fibers and conversely 80-20 weight percent ofmulti-component fibers, the latter incorporating anti-microbial agentsas described herein, the layer weight in 2.5-9.0 oz. per square yard.The layer is non-woven needle-punched fabric with some distinct fiberorientation in the lateral direction within layer 214 itself and withpunched through fibers from the next lower layer as described below.This layer 214 is bonded to layer 212 by a an adhesive web of scrim ormesh form of 15-28 gm per sq. meter weight (very diaphanous) and made ofpolyester, polyolefins (polethylene, polypropylene, etc.), polyamide orother fiber materials and in the course of laminate heating and pressingbecomes an effective bonding agent to bond layers 212, 214 securely toprevent de-lamination in service use.

[0438] The next major layer 216 is designed as a moisture storage (andeventual off-gassing) layer with high surface area fibers, including20-50 weight percent of 4DG lobed or grooved fibers of polyester orother fiber material of a type well known per se, 50-60 weight percentof normally surfaced polyester mom-component fibers and 5 to 25 weightpercent of bi-component fibers containing anti-microbial agents. Thebi-component fibers are preferably normally surfaced but could also bemade of grooved form, consistent with the missions of anti-microbialagent carriage and access. The layer as a whole weighs 4-12 oz. per sq.yard and is bonded to layer 214 by deep needle-punching fibers of layer216 into layer 214 using barbed felting needles to establish lateralwicking paths as indicated, e.g., at 216L.

[0439] The final layer 218 is a co-extruded two part plastic film with abarrier sub-layer portion 218A and a bonding sub-layer portion 218B,each such portion being 25-100 microns thick and made of A/Bcombinations of, e.g., polypropylene/polyethylene,polypropylene/polyester, polyropylene/polyamide, etc.

[0440] When the laminate is heated and pressed under state of the artconditions for molding such materials the layer 214 becomes highlydensified and entraps the lateral fibers 216L to secure layers 214, 216together while bonding layers 215 and 218B secure the outermost layersto the laminate.

[0441] The tough upper layer 212 resists cracking and shedding under theimpact of direct user contact and flexing in use or when removed from ashoe but allows free flow of moisture vapor which is wicked throughlayer 214 to moisture storage layer 216 in an efficient way and retainedthere because of the bonded on moisture barrier 218A so that odordoesn't go beyond the innersole to any substantial degree. The overallresult is an odor absorbing innersole of fibrous material that providesnecessary cushioning in a slim profile that can fit comfortably in anathletic or dress shoe or boot or moccasin/loafer. No foam materials orcharcoal adsorbents or the like need be used. Moisture can be absorbedin the present product and retained with high destruction of odorcausing microbes and the moisture can desorb gradually with loweredconcentrations of odor causing microbes with two to three order ofmagnitude reduction.

[0442] Nautical Fabrics

[0443] Nautical fabrics can be made at least in part using theanti-microbial fibers of the present invention and are particularlyuseful for this type of application in which the fabrics are constantlywet and subject to mildew; and

[0444] Moldable Laminates

[0445] Moldable laminates for footwear may also be produced as part ofthe present invention. A binding agent is provided in a nonwoven productin which the binding agent is a thermoplastic binder fiber orbi-component binder fiber. The binder fiber is thermally activated inorder to bind (stiffen) the nonwoven portion of the product. Since thisis produced with 100% thermoplastic components allows for easyrecycling. The product is a thermal moldable impact resistant stiffenerfor footwear applications such a counter or box toe.

[0446] A 100% thermoplastic, stiff reinforcing multiple laminatestructure which can be moldable into complex, compound shapes andbondable via a thermoplastic hot melt adhesive to a carrier surface tobe reinforced to provide a tough, water resistant reinforcement, usablefor instance in stiffening applications as a footwear counter or box toereinforcement element that is recyclable into itself. The fabric layeris in part geometrically locked into the tough thermoplastic resinlayer.

[0447] As shown in FIG. 26, the product comprises a tough extruded coreof thermoplastic resin such as ionomer, EVA or styrene stiffened ionomerand at least one impact resistant strength layer of nonwoven.

[0448] The needle punched nonwoven is manufactured from a bi-componentstaple fiber or blend or PET staple fiber and binder staple fiber orblend of PET staple fiber and bi-component staple fiber. The nonwovenutilizes a combination of PET fibers and PETG or other copolymer orhomopolymer fibers that act as a binding agent for PET. The staple fiberis 4-15 denier and 38 to 76 mm in length.

[0449] The thermoplastic components of the product are either miscibleor mechanically compatible so as to allow for homogenization andincorporation into the extruded thermoplastic core thus allowing forcomplete recyclability of scrap material.

[0450] The binder fibers have a low melting temperature, and the fiberportion of the product is prepared as disclosed elsewhere herein.

[0451] It will now be apparent to those skilled in the art that otherembodiments, improvements, details, and uses can be made consistent withthe letter and spirit of the foregoing disclosure and within the scopeof this patent, which is limited only by the following claims, construedin accordance with the patent law, including the doctrine ofequivalents.

What is claimed is:
 1. A multi-layer footwear component, including: atleast a first layer comprising multi-component fibers of thermoplasticpolymers further comprising a core of thermoplastic polymer being atleast 20 and less than 70% of the fiber by weight, and a sheath beingmore than 30% of the fiber by weight and including (i) a thermoplasticpolymer and (ii) an anti-microbial/anti-fungal inorganic additive beingfrom 0.1% to 20% by weight of fiber, the thickness of the sheath inmicrons being approximately two times the nominal particle size inmicrons of the additive; and at least one further layer.
 2. The footwearcomponent of claim 1, forming an insole, midsole, box toe, counter, orlining.
 3. The footwear component of claim 1, wherein the anti-microbialfiber is used in the layer which is nearest the foot of a wearer.
 4. Thefootwear component of claim 1, further comprising a support layer oflatex attached to the layer containing the anti-microbial fiber.
 5. Amulti-layer laminate of high porosity between two internal layersthereof, one of which is bonded to the other with lateral fiberstraversing parts of both layers, one or both of such layers includingmulti-component fibers of thermoplastic polymers, each fiber including acore of thermoplastic polymer being at least 20 and less than 70% of thefiber by weight, and a sheath being more than 30% of the fiber by weightand including (i) a thermoplastic polymer and (ii) ananti-microbial/anti-fungal inorganic additive being from 0.1% to 20% byweight of fiber, the thickness of the sheath in microns beingapproximately two times the nominal particle size in microns of theadditive, and means for acquiring moisture vapor into the laminate andtrapping it there, one of the internal layers having higher strengthproperties than the other and the other having a higher moistureretention capacity.
 6. The laminate of claim 5, formed as aninsertable/removable insole for a shoe or the like.
 7. An anti-microbialfootwear component, including: at least a first layer comprisingbi-component fibers further comprising a core of a high tenacity polymerbeing at least 20 and less than 70% of the fiber by weight, and a sheathof a hydrolysis resistant polymer being at least 30% of the fiber byweight, and including an additive ranging from 0.1% to 20% by weight ofthe fiber and being selected from the group consisting of pigments,compounds creating a hydrophilic surface, and anti-microbial,anti-fungal and anti-odor materials; and at least one further layer. 8.The footwear component of claim 7, formed as an insole, midsole, boxtoe, counter, or lining.
 9. The footwear component of claim 7, whereinthe anti-microbial fiber is used in the layer which is nearest the footof a wearer.
 10. The footwear component of claim 7, further comprising asupport layer of latex attached to the layer containing theanti-microbial fiber.
 11. A multi-layer laminate of high porositybetween two internal layers thereof, one of which is bonded to the otherwith lateral fibers traversing parts of both layers, one or both of suchlayers including bi-component fibers of thermoplastic polymers, eachfiber including a core of thermoplastic polymer being at least 20 andless than 70% of the fiber by weight, and a sheath being more than 30%of the fiber by weight and including an additive ranging from 0.1% to20% by weight of the fiber and being selected from the group consistingof pigments, compounds creating a hydrophilic surface, andanti-microbial, anti-fungal and anti-odor materials. and means foracquiring moisture vapor into the laminate and trapping it there, one ofthe internal layers having higher strength properties than the other andthe other having a higher moisture retention capacity.
 12. The laminateof claim 11, formed as an insertable/removable insole for a shoe or thelike.
 13. A multi-layer footwear component, including: at least a firstlayer further including a binder fiber made from low temperature polymerwith a melting or softening temperature below 200 degrees C.; ananti-microbial additive of an inorganic compound made from a metalchosen from the group consisting of copper, zinc, tin and silver addedto the binder fiber, the additive ranging from 0.1 to 20% by weight ofthe fiber, and fibers which are free of anti-microbial additive beingblended with said binder fiber, said blend of fibers having been heatedto its melting temperature, thereby providing a fiber blend which can beused to produce an anti-microbial finished fabric able to withstandsignificant wear and washings and maintain its effectiveness; and atleast one further layer.
 14. The footwear component of claim 13, formedas an insole, midsole, box toe, counter, or lining.
 15. The footwearcomponent of claim 13, wherein the anti-microbial fiber is used in thelayer which is nearest the foot of a wearer.
 16. The footwear componentof claim 13, further comprising a support layer of latex attached to thelayer containing the anti-microbial fiber.
 17. A multi-layer laminate ofhigh porosity between two internal layers thereof, one of which isbonded to the other with lateral fibers traversing parts of both layers,one or both of such layers including a binder fiber comprising a lowtemperature polymer with a melting or softening temperature below 200degrees C., an anti-microbial additive of an inorganic compound madefrom a metal chosen from the group consisting of copper, zinc, tin andsilver added to the binder fiber, the additive ranging from 0.1 to 20%by weight of the fiber, and fibers which are free of anti-microbialadditive being blended with said binder fiber, said blend of fibershaving been heated to its melting temperature, thereby providing a fiberblend which can be used to produce an anti-microbial finished fabricable to withstand significant wear and washings and maintain itseffectiveness. and means for acquiring moisture vapor into the laminateand trapping it there, one of the internal layers having higher strengthproperties than the other and the other having a higher moistureretention capacity.
 18. The fabric of claim 17, as aninsertable/removable insole for a shoe or the like.